What do ports, construction contractors, and utilities companies have in common? They all employ crane operators—and they’re increasingly using simulation to train them.
There are many reasons to include simulation in crane operator training programs. To start with, simulation drastically reduces the likelihood of a safety incident occurring during training. A crane operator who makes contact with a power line in a simulated environment, for example, can learn from their mistake and try again. By contrast, that same mistake with real equipment on a real worksite can have devastating consequences.
This safety benefit on its own is often enough for many to consider crane simulators a worthy investment. But the benefits don’t just end there. In fact, there are several key advantages to using simulation in crane training programs.
Crane simulators and the simulations that power them provide faster and more effective training. There are several reasons for this. To start with, simulation offers concentrated practice that could take weeks or even months to complete on real equipment. Train for rare and specific scenarios without having to wait for them to happen. And, factors like weather, equipment availability, and trainer availability do not necessarily have to stop training efforts. With Intellia, a next-generation Intelligent Training System, custom learning paths allow operators to complete lessons at their own pace.
Set up and clean up before and after exercises also become negligible with simulation. In fact, when switching between equipment types, all it takes is a quick change of the controls, which can be accomplished in under a minute.
Each of these aspects of crane simulation training work together to dramatically reduce training times. At the construction contractor Conewago Enterprises, for example, simulation helped reduce crane operator training times significantly from six months to seven weeks.
Simulation allows for better corrective training, as instructors don’t have to resort to shouting instructions to operators sitting in the cab. Rather, they can provide their instructions while standing next to the student, or review exercise data after a session to provide objective insights on what went wrong.
For training schools, the ability to provide better corrective training is enormous. John Kelly, the Training Center Manager at The National Construction Training Centre, values the ability to quickly correct errors in the moment. “Simulation training does a brilliant job of allowing for corrective training on the spot,” he said. “You don’t have to come down off of a crane and go into a classroom. The instructor can provide corrective training right then and there while literally standing next to the student.”
Including crane simulators in operator training programs can drastically improve productivity. At the family-run port operations company ZHD Stevedores, for example, operators were able to halve the amount of time they took to move bulk material. Rather than take 40-60 minutes to move 550 tonnes of bulk material, they were able to do it in 20-30 minutes.
How is this possible? In part, it’s due to the concentrated practice and objective data operators can access through simulation training. With simulation, it’s possible to practice the same lift over and over again at a much faster pace than on real equipment. And with the detailed data trainers receive from an Intelligent Training System, they can identify precisely which areas need the most practice to improve productivity.
Training with crane simulators offers environmental benefits. This is because traditional crane training requires the use of fuel-powered machinery. Simulators, on the other hand, require no fuel and produce no emissions. By swapping machine time with crane simulator time, trainers can cut fuel consumption. This helps organizations reduce their carbon footprint.
By incorporating crane simulators into safety training, organizations demonstrate a commitment to operator safety and wellbeing. How does this improve operator retention? According to a recent study by Duraplas, nearly half of American workers (48%) would consider taking a pay cut for a job with a better safety culture. When it comes to work as a heavy equipment operator, where safety incidents can and do lead to fatalities, these insights are even more poignant.
But that’s not the only way that simulation training improves operator retention. Because simulation provides quick and effective training, it’s a top choice in upskilling and cross-skilling initiatives. With Intellia the Intelligent Training System, for example, custom learning paths can be designed specifically for experienced operators. This makes it easier than ever for organizations to provide clear career progression for dedicated employees and increase the likelihood that they’ll stay and grow along with them.
All of the benefits above translate into significant cost savings. Lower fuel consumption, faster training times, and enhanced productivity combine to drastically reduce training and operating costs, improving profits. At Conewago Enterprises, for example, simulation reduced crane operator training costs by over 60%, from $40,000 to $15,000.
In addition to these savings, simulation’s ability to reduce the likelihood of a safety incident has the potential to save millions in avoided fines, lawsuits, brand reputation damage, low employee morale, and equipment damage.
As we briefly discussed, one of the most appreciated benefits of crane simulator training is its ability to improve safety. Because safety is so important to crane operation, it’s worth revisiting this benefit in a little more detail.
By providing a risk-free environment for operators to learn and practice, simulation helps reduce the likelihood of accidents and injuries during training. Operators can familiarize themselves with crane controls, learn to handle challenging scenarios, and develop a strong understanding of safety protocols, all without the dangers associated with real-life training. Operators are also able to make mistakes without causing damage or injuring themselves:
In addition, simulation offers a crucial advantage that simply can’t be replicated through other training methods: the ability to practice rare and dangerous scenarios. The distinct feeling just before equipment tips, the dangers of windy conditions, and contacts with power lines—these and other scenarios are difficult if not impossible to safely practice on real equipment.
Detailed reporting and safety metrics in crane simulations also highlight any safety violations that occur in exercises, including rough load handling and when a load passes over a person. These safety considerations are all the more important in the context outlined by a recent Census of Fatal Occupational Injuries, which indicated that nearly half of workplace deaths involving cranes include workers being struck by objects or equipment.
Yes. The type of simulation training made possible by a crane simulator allows for measurable benefits in training time reductions, improved corrective training, enhanced productivity, reduced emissions, cost savings, operator retention, and accident avoidance. It is a solution that positively impacts many aspects of an organization’s operations, and has the potential to pay for itself quickly.
Want to learn more about the ROI of simulation training? Check out our ebook on Measuring the ROI in Simulation-Based Training.
