Simulation training
No material and machine running time costs
The entry-level printing staff at Willamette Industries' preprinted liner board factory in Richwood, Kentucky, USA often spend a lot of time in a virtual world. They are cruising the world not for entertainment, but for technical training, which aims to lay a solid foundation for flexographic printing skills. Sinapse's innovative Flexo Press Simulator opened the door to another higher level of understanding for them. Tom Thackeray, the production manager of the plant, served the development team of the simulation system and is now responsible for developing training courses for 6 trainees.
Thackeray is also responsible for their progress measurement. When asked about the impact of purchasing and installing the simulation system on the enterprise and what contribution he made to the training course, he listed the following without hesitation: "Higher productivity, shorter printing downtime, stronger Problem-solving skills, increase feelings among colleagues, and a more pronounced positive and confident attitude. "
Thackeray said: "Preparation before printing has become faster. The device cleaning has become faster. The team (all 20 printing employees work in 3 shifts) has cooperated much better than before. This allows training staff without materials and A good way of running time cost of the machine. The problem solving ability of this simulation system is stronger than any training equipment we used in the past. "
During the exercise (the exercise program has been programmed into the flexo printing press simulation system by Thackeray), the trainers of Willamette can adjust the anilox roller imprint and flat plate imprint. They can also maintain consistent ink viscosity by cleaning the filters and pumps of the ink system. Stripe can be eliminated by adjusting the doctor blade. Knowledge of the simple registration control procedures will be tested by the specified challenges.
According to Thackeray, the team's training of 6 members is still in progress. None of these 6 people have any experience in flexographic printing, nor do they understand how the factory ’s 6-color Fischer & Krecke central imprinting press for wide format applications works. "Each person trains on the simulation system for 30 to 40 minutes at a time. Depending on the workload, we arrange 2 to 3 trainings per person per week."
Thackeray admits: "It is impossible to find someone who understands flexographic printing technology at the moment. All we have to do is get some people to receive training in this area. Obviously, we have a fast success rate. The staff turnover is
Willamette is not a big problem. We generally only lose 1 employee every 2 years. This is very rare in the extremely competitive printing industry. Nevertheless, the simulation system has helped us save training costs. â€[Next]
Willamette's production department manager pointed out that the flexo printing press simulation system is absolutely user-friendly. He praised: "No one will find it difficult to operate. Every employee participating in the training program has certain computer skills when joining this team. Everyone knows how to use the mouse, which is all the conditions required. . "
But Thackeray also said that the trainees obviously need to spend a little time learning all the control operations and their respective uses. "This is certain." The production manager said that the flexo printing simulation system was absolutely in line with expectations. "This is the only factory in Willamette that is equipped with a simulation system. I suggest that other factories should also be equipped with this system, especially the box factory. Willamette has a total of 42 corrugated paper factories." To some extent, it reduced some of the costs incurred by on-the-job training (such as material costs and downtime). On-the-job training solves problems arising from work as needed. "
With the help of the simulation system, Thackeray has developed a more formal and stricter review and employee evaluation procedure. "Before entry-level employees are promoted, they must pass a test aimed at raising their wages. The simulation system is part of the test procedure. To date, several people have been successfully promoted, and several others are about to enter the next round Review. "
Thackeray himself has just participated in the trainer training project related to the simulation system. He said: "This is a very good experience. I really hope to take others with me. The biggest gain from my training is that my ability to arrange exercises and courses has been fine-tuned."
Willamette Production Director pointed out: "Now, it takes only 30 to 40 minutes to develop a simple exercise. Once it is determined, it can be used repeatedly."
Talking about the next few steps of the development of Willamette's flexo printing press simulation system training project, Thackeray said: "The only thing I have to do is to complete the setting of different courses. These courses are for our employees to complete the The procedures and the development of them from entry-level trained employees to professional printing operators are indispensable. Once the course is finalized and put into use. From now to the implementation, my time is very urgent. I expect to be in the next few Complete our entire project within a month. "
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