Operator Training Simulator for Milk Powder Production Processes

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Presentation transcript:

Operator Training Simulator for Milk Powder Production Processes The Virtual Powder Plant Operator Training Simulator for Milk Powder Production Processes Michael Robinson – Manager, NCDEA Gilbert Chandler Centre

Project sponsors

The Victorian Dairy Industry: Milk Powder Production Dairy based powders account for over 36% of Australian dairy industry manufacturing Milk powders contribute over $1 billion in export income to Victoria Reference: Dairy Australia; ABARE

Powder Manufacturing Systems Large, complex and diverse operations Difficult for new staff to master Offer challenges in process optimisation Highly automated, with hidden sequencing steps Equipment is remote from operator terminals

Skilled operators for industry

The Simulator The development of an Operator Training Simulator to provide operational staff with: training and competency development a tool for observing the changes in both manufacturing operations and product parameters in an interactive system a guide for operational changes in manufacturing

The typical Operator interface – Murray Goulburn Cooperative Ltd Rochester site

Focus: Operations & Supervisory Staff Improved understanding of the plant activities Analysis of signs and signals Early recognition of problems Fine-tuning tools Plant optimisation capacity Problem prevention and problem solving capability

Outcomes: The Simulator The Package Modelled on Murray Goulburn Coop Ltd Rochester Fidelity Operating Manuals Engineering tools Data capacity Process Trend Charts Remote Connection Networked VPN access (dongle activated)

Learner interface – evaporator simulator and operation procedure

Learner interface – dryer simulator and operation procedure

Outcomes: Delivery Class Usage Remote access Diploma & Grad Cert programs – blended delivery Certificate II & III – Food Processing Remote access Elluminate on-line usage Remote access from workplaces Control room access Firewalls, ownership & licensing

Implementation - Outcomes for the Dairy Industry For operator training the Simulator will facilitate: Improved operator performance Reduced wastage and rework Improved product quality and plant performance Reduced plant downtime Reduced operational costs Improved profitability

Future developments Interface simplification Parent plant layout with core information and buttons Overlay of scripted scenarios CadSimPlus direct HTML linkage of Operating Manuals Further development of knowledge base linkages to HTML Operating Manuals

Project Contributors Clean Technology Solutions Pty Ltd