Using simulator technology to teach rookies and retrain experienced crane operators

Q&A on the Real Value of Simulator Training

Training and instructional technologies professionals from Crane Industry Services, LLC (CIS) and CM Labs Simulations recently discussed the benefits of using simulators to train crane operators. Becky Schultz, editor of Equipment Today interviewed Debbie Dickinson, CEO of CIS, and Drew Carruthers, Construction Product Manager for CM Labs. Access the archived webinar here.

At the conclusion of the presentation, participants asked questions about the real-world transferrable skills to be gained through simulation training, as well as current trends in the technology. In the coming months, an ongoing study to determine the value of simulators, which is being conducted by CIS and CM Labs, in partnership with West Georgia Technical College, will reveal additional insight.

Debbie Dickinson

Drew Carruthers

Transferrable Skills

Q: Are the skills learned on a simulator transferrable to a real crane? 

Carruthers: Absolutely. When you are sitting in a simulator that behaves like the real thing — down to that “seat of the pants” feel — in combination with realistic training scenarios, you are learning how the equipment responds to your judgement and awareness. This is critical for learning how to operate safely and efficiently.

Q: Is there an opportunity to customize the simulations to specific scenarios relevant to the organization? 

Dickinson: Yes, CM Labs customizes the simulator programs and challenges presented to operators.  If needed, CIS can provide customization input based on employee qualification levels and scope of work. For example, in an electrical substation scenario, a portion of the environment is designated as “live.” If an operator maneuvers the load too close to the “live” area, the instructor may give the operator’s seat a jolt or cause a warning to flash on the screen.

In steel erection applications, customization might include multiple environmental factors, such as vehicle and pedestrian traffic and minimal work space between buildings. To quote Derrick Moore, Georgia Tech football staff, “Anyone can make a touchdown in a wide open field.”  Simulations provide operators opportunities to experience unique work site challenges and learn how to respond without risking personnel, crew, or public safety.

In addition, instructor can inserts unexpected changes during a normal, non-customized simulation to allow us to evaluate how the operator reacted to the unexpected.

Q: How can you teach someone the communication skills required in a simulated setting, such as using radio or hand signals?

Dickinson: An operator using a simulator is expected to react to signals given as part of the safe load movement. For example, the operator may be required to operate in the blind, following only the hand or voice signals given by the rigging crew. The operator’s speed to the complete task, as well as accuracy in controlling the load, when working at the direction of the crew, is recorded by the simulator.

Q: Has the industry done any research on the occurrence of negative transfer for some situations?

Dickinson: Some operators may view simulation training as a high-end video game rather than the serious training exercises that Vortex simulations provide. As the Federal Aviation Administration has done, industries utilizing simulation training need to set standards for the time and achievement level outcomes expected to measure the value. Findings from the research in progress will help set those standards.

In other industries, simulators have been shown to provide objective and consistent learning methodologies with proven results, including faster time to competency, skilled and safe operators, and more effective assessment. The benefits far outweigh the negatives, and in fact, can be used as refresher for experienced operators to identify and correct bad habits.

Technology Trends

Q: On what types of construction equipment is simulator training available?

Dickinson: The simulators being used in the research include exercises on Excavators, Mobile Cranes, and Tower Cranes.

Q: Is it possible to train multiple individuals as a team with simulators?

Carruthers: Yes. Networked simulation is what powers Vortex Simulator team training and instructor stations. Some of our most popular training scenarios include full team training, with signaler/rigger stations, or tandem lifts. Other clients of ours are also using the sim so the whole crew can experience the lift virtually, from the operator seat. They say this ensures that everyone is on the same page about what needs to happen and when.

Q: There seems to be a contradiction between “the higher the fidelity the better,” and the statement that “bigger is not necessarily better” – i.e. that one should not fall in love with technology. How do you establish a minimum acceptable level of fidelity? 

Carruthers: The “love” of technology should be grounded in value. In addition to great graphics, Vortex simulators simulate machine operation from the set-up of the operator’s chair, controls and visual perspectives. Technology has to look, feel and closely replicate machine experiences to be worthwhile.

Q: Is today’s technology sufficient to run a physically accurate simulation without large/expensive specialized hardware? 

Carruthers: Great question! Our goal is to create a simulator that engages the operator in the training experience. It has to look real and feel real, otherwise the operator is simply learning skills and responses that will need to be unlearned at the worst possible moment — on the job site!

That’s why our question is always: Is the trainee learning skills that will be transferable and useful on the worksite? If yes, we’re doing a good job. If not, it can be a detriment to productive training.

Some simulators highlight game technology. CM Labs does not.  Vortex simulations use an engineering-grade simulation engine — the same one used by equipment OEMs — to simulate the machine, soil and load dynamics. Fidelity of the simulation is critical to learning real skills and not just how the controls work. Fidelity also comes from the learning exercises themselves. In Vortex simulators the training exercises progress from introductory to real and challenging worksite situations — along with machine faults, bad weather and worksite hazards. It helps prepare you for the whole job, not just pulling levers!

Q: What sorts of replay capabilities are typical, and how quickly can variables be played back? Is it common to play back the results of a simulation to the operator, as a training technique?

Carruthers: We believe strongly in the whole learning methodology of Plan, Do, Review. Simulators can support this methodology very effectively. Before using the simulator you can PLAN the operation, then using simulators DO the operation and finally, with the crew you can play-back and REVIEW the simulation exercise. That last step is critical to learning and something that is hard to do with the real machines. Pilots and soldiers have been trained using these techniques for decades. It works and is efficient.

Q: Is the simulation training available worldwide and does it count towards operator hours? 

Dickinson: Yes, simulation technology is available worldwide. Different government agencies require different amounts and levels of training for certification or licenses. In some jurisdictions, training hours count toward operator hours. The study’s results will determine the validity of simulator training.