Modern mining companies understand that introducing high-fidelity simulator systems into the training curriculum is a quick and cost-effective way to significantly improve the skills and, in turn, the productivity of equipment operators, says surface and underground mining simulator developer ThoroughTech.

Skills development through simulator training is done by providing operators with a safe, controlled environment in which they can learn and practise vehicle functionality, equipment controls, instruments and correct operating procedures, without the possibility of vehicle damage or personal injury, notes ThoroughTec.

The benefits of simulator systems to the mining operator can be broken down into four categories – safety, productivity, cost savings, and recruitment and skills development.

On some of the company’s simulator systems, such as the ThoroughTec Cybermine fourth-generation simulator systems, operators are also able to experience emergency situations, such as brake failures and engine fires, without risk to person or property. If these situations were to occur in reality, the operators would have the know-how to correctly respond.

“Further, trainees are able to operate in all weather conditions and all times of day. The training develops an operator that is more aware of surroundings and possible dangerous situations, which, in turn, ensures lower accident rates and accident severity,” says ThoroughTec.

The most obvious example of simulators improving productivity is that heavy equipment remains available to perform its primary role, rather than being taken out of the production cycle for training.

Further, when one considers the risk of damage to heavy equipment in the hands of unskilled trainee operators, and the resultant unavailability of that equipment, as well as repair costs and machinery down time, the use of simulators proves to be a wise option, says ThoroughTec.

Productivity is also directly improved by having more proficient and efficient operators. Not only are the operators more efficient at performing their core tasks, but the reduced incidences of accidents and resultant downtime, in the case of both personnel and machines, means an increase in productivity.

Further, the wear and tear on the actual machinery is reduced, as operating costs such as fuel are removed.

South African miner Gold Fields reported a significant decrease in the amount of time required to train an operator to full competence at its South Deep mine, near Westonaria.

Since integrating Cybermine fourth-generation simulators into its training programme, the South Deep mine has reduced the amount of time spent on training from three weeks on the actual machine, to just one week of simulator training and only a few days of actual machine training.

“Gold Fields also found that operators who had completed simulator-based training outperformed those who had been through conventional training,” says ThoroughTec.

Meanwhile, in terms of personnel recruitment, simulators have also been successfully used as an integral part of the screening process.

The world’s largest gold producer, Barrick Gold, used a Cybermine fourth-generation simulator to appraise many prospective employees to substantiate the claims made on their job applications. The gold producer found that just one session on the simu- lator was sufficient to distinguish the star employees from their inexperienced counterparts, eliminating the costly risk of employing a below-par machine operator.

Further, instructors on Cybermine fourth-generation simulators are able to set specific tasks for trainees, record their results in a central database, export these results or even print them directly, making the comparison of a number of potential employees a simple matter.

ThoroughTec maintains that the use of simulators is not limited to inexperienced operators or for testing purposes only, as experienced operators also need to learn new skills when new technology is released, to refresh their existing skills and to eliminate bad habits that they may have picked up.

ThoroughTec also cites challenges experienced by diversified engineering group Sandvik. The company was experiencing excessive breakdowns of its machines at a mine site and was unable to identify any mechanical fault.

Sandvik suggested that the mine operators refresh their skills on the Cybermine fourth-generation simulator. It was discovered that many operators were scoring high on the fault ‘used the accelerator and brake pedal simultaneously’, owing to the operators resting their foot on the brake pedal instead of the foot rest, which caused an increase in wear and tear.

On completion of the simulator training course, the problem disappeared and the mine site enjoyed a considerable reduction in maintenance costs.
ThoroughTec believes that not all simulator systems offer the same degree of training. High-fidelity simulator systems, such as the Cybermine fourth-generation, are able to replicate a wide variety of training scenarios and offer an all-encompassing training solution, while other simulator systems are less realistic and offer limited training benefits for certain tasks.