Presentation To
Simposio Internacional en Logística y Desarrollo Portuario
Advanced Training Solutions for Maritime Terminals 8 May 2009
Why Simulation How Ports Use Simulation Types of Simulators Demonstration Questions & Answers
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WHY SIMULATION?
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Reduced training on live equipment Opportunity cost of taking live equipment off-line z Operating, maintenance & environmental costs z Accident/liability costs of novice operators operating expensive/complex equipment z Instructor works with more than one student at a time z
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More Effective Training Reduced overall training time Ability to repetitively practice complex and difficult scenarios (dangerous and impractical to practice live) Increased new operator productivity
Ability to objectively screen/assess operators
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History of Simulation in Training Distant Past z
Simulation utilized only when operational errors meant certain loss-of-life and/or total-loss of expensive equipment. • Military Driven
Recent Past z
Simulation utilized to reduce risk and increase efficiency • Adoption by most Commercial Airline Fleet • FAA qualifies ALL pilots using Simulator Aided Training • Simulation primarily trained functional skills (what levers, knobs, buttons to push & when)
Now (Present) z
Many industries use simulation training as a tool to drive cost reduction and operational efficiencies. • Planes, cranes, trains, ships, earth moving, mining equipment, research, etc. • High fidelity simulation allow for both procedural and skills training.
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Past Impediments to Simulation z
THEN: 1) System Costs (Millions of $$$) 2) Questionable Fidelity 3) Delivery Schedules (System Usually Obsolete Before It Was Delivered) 4) Expensive to Maintain and Difficult to Upgrade 5) Extremely Technical to Operate
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NOW: 1) PC-Based—Pricing continually declining as tech improves 2) Vastly Improved Realism 3) Quicker Turn Around 4) Reliable & upgradeable off-the-shelf subcomponents 5) Point and Click intuitive operability
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Results of Improper Training
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Crane operator learning curve
Proficentcy Proficentcy
Learning curve Learning curve 100 100 90 90 80 80 70 70 60 60 50 50 40 40 30 30 20 20 10 10 00
Accidents most likely to occur
10 11 11 12 13 14 15 16 17 18 11 22 33 44 55 66 77 88 99 10 18 19 19 20 20 21 21 22 22 23 23 24 24 25 25 26 26 27 27 28 28 29 29 30 30
Training days 9
Actual Simulation Results Case Study #1 (Port of Antwerp) – z
Reduction in Training Time of 20%
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Increased Student Efficiency 25% during first 30 days
Case Study #2 (Port of Hamburg) – z
Decreased Training on Live Equipment >50%
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Increased Instructor/Student Ratio 1:1 to 1:3
Case Study #3 (US Army) – z
95% Reduction in Property Damage & Personnel Injuries
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400% Reduction in Time to Perform Complex Operations
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Actual Simulator Results Case Study #4 – • Annual Recurring Cost to Train on Real Equipment - $1,144,609 • Annual Recurring Cost to Train on Simulator - $281,784 • Annual Training Cost Savings - $862,825
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HOW PORTS USE SIMULATION (CURRICULUM DEVELOPMENT STUDENT ASSESSMENT)
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Benefits of Computer-Based Curriculum •
Ability to modify curriculum in real time based on immediate empirical feedback •
Some ports’ trainee failure rate is as high as 50%
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Customize exercises for a specific trainee or issue
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Full automation of: • Trainee progress • Trainee evaluation •Automatically compared against a set of criteria • Data collection
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Trainee can learn crane basics on the computer
Curriculum Is Built Into Simulator 13
Curriculum Flexibility Lesson 1
Scenario 1
Scenario 2
Scenario 3
Lesson 1 Scenario 2 Scenario 1
Automatic or Manual analysis
Scenario 3 14
Optimal Path—STS Crane
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Most Recent Path—Straddle Carrier
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Control Stick Analysis Tool
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Joystick Analysis tool Joystick Effeciency per second
80 60 40 position
% Joystick Movement from previous
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20 Novice
0 -20
1
3
5
7
9
11
13 15
17 19 21
23 25
27 29
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Expert
-40 -60 -80 -100 Seconds
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Analysis Tools 1)
Container Path optimization
2)
Timed Performance/Efficiency
3)
# of Major/Minor collisions
4)
Control Stick Analysis (Operational skills)
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Instructor Assessment (requires Instructors Presence) 40 35 30 25 20 15 10 5 0 1)
2)
3)
4)
5) 19
Global Crane Simulators
-ML5000 -ML4000 -ML2000 -ML1000
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TYPES OF SIMULATORS
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No Limit to Simulated Equipment
MasterLift™ Product Line z ML1000 (Portable) z ML2000 (Midsize) z ML4000 (Reconfigurable) z ML5000 (Straddle Carrier) z ML6000 (Combination) z Container & Cargo Crane Types ¤ Dock Gantry (STS) Crane ¤ RTG Crane ¤ RMG Crane ¤ Mobile Harbor Crane ¤ Ship Pedestal Crane ¤ Reach Stacker ¤ Mobile Jib & Jib-Boom Cranes ¤ Ship Gantry Crane ¤ Cargo-only Crane Types ¤ Mobile Lattice Crane ¤ Hydraulic Telescopic Crane ¤ Tower Crane 22
Portable “Suitcase” Simulator
• Ideal for introductory training • Ideal as a complimentary training system for other MasterLift products. • Rugged aluminum Case with Generic Crane Controls • Available in Multiple Crane Configurations • Models all Crane Movement and Load Interactions • Models Environmental Effects • Full Collision Detection and Response 23
Mid-Sized Simulator • Specific Crane Controls • Available in Multiple Crane Configurations • Models all Crane Movement, Load Interactions, and Environmental Effects • Full Collision Detection and Response
• • • • • •
Single Channel Visual System 3 Degree-of-Freedom Electric Motion Platform Full Feature Instructor Station Instructor Control and Monitoring Instructor Induced Malfunctions Instructor Controlled Animated Signalman 24
Mobile Simulator Configurations
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Simulator/Classroom Combination
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Fully Enclosed Cab • Specific Crane Controls • Available in Multiple Crane Configurations • Models all Crane Movement, Load Interactions, and Environmental Effects • Autonomous, Path-Driven Traffic • Full Collision Detection and Response
• • • • • •
Four (4) Channel Visual System 4 Degree-of-Freedom Electric Motion Platform Full Feature Instructor Station Instructor Control and Monitoring Instructor Induced Malfunctions Instructor Controlled Animated Signalman 27
Types of Simulators
Port of Marseille, France
Port of New York/New Jersey
Port of Hamburg, Germany
Port of L.A./Long Beach 28
Full Immersion—Dome
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Full Immersion—Dome
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Full Immersion--Dome
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Typical Student Controls
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Mobile Jib Crane with Clamshell
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Mobile Jib Crane with Cargo
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Full Immersion—Flat Panels • Specific Straddle Carrier Controls • Models all Straddle Carrier Movement, Load Interactions, Surface Interactions, and Environmental Effects • Full Collision Detection and Response • Autonomous, Path-Driven Traffic
• Six (6) Channel Visual System • 6 Degree-of-Freedom Electric Motion Platform • Full Feature Instructor Station • Instructor Control and Monitoring • Instructor Induced Malfunctions • Instructor Controlled Dispatching 35
Straddle Carrier Operator’s View
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Typical Student Controls
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Full Immersion
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STS Crane Operator’s View
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SIMULATOR FEATURES
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RTG Visual Scenes
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Mobile Harbor Crane (Gottwald)
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Reach Stacker
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Cargo Selection
Containers
General Cargo
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Multiple Container Types
40 ft. Stack Flat 20 ft. Open Container
20 ft. Container
40 ft. Open Container
40 ft. High Container 40 ft. Container
40 ft. Reefer Container
20 ft. Tank Container
20 ft. Stack Flat Container
20 ft. Reefer Container
45 ft. High Container
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Specialized Containers/Attachments
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Multiple Ship Types
Container Feeder Ship
Super Post Panamax Ship
Multiple Post-Panamax Ships
Barge
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Yard Traffic Options
Empty Container Handler
Straddle Carrier
Train Cart
Truck Off Road Pin Trailer Truck and Skeleton Trailer
Stationary Bomb Cart Trailer
Off Road Keyed Trailer
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Sample of Available Traffic Models
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Typical Visual Scene
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MasterLift™ Instructor Station
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Typical Control Panel (Mimic Screen)
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Typical Control Panel (Situational Awareness Display)
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Ship Configuration
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Instructor Operator Station (Environmental Page)
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Flexible Crane Configuration
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Instructor Operator Station (Statistics Page)
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Instructor-Induced Malfunctions
Straddle Carrier Malfunctions
59 STS Crane Malfunctions
SimFusion™ Option • Fully Integrated Training Environment • Scalable - Individual Operator Training - Full Team Training • Simultaneous Simulator Controlled and Computer Controlled Traffic • Full Collision Detection and Response
• Local Area Networking (LAN) • Home Port Specific Virtual Environment • Multiple Student Stations Controlled by a Single Instructor Station
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SCENARIO CREATION
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Scenario Creation Container ship choices Super Post Panamax ship Feeder Ship, Container Barge, adjacent to Feeder Ship
adjacent to Post Panamax vessel
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Scenario Creation Choice of Way Point actions
Adjustable Way Points
Single truck routed to transport containers between QC/RTG QC
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More Complex Scenario Creation
More complex scenario with 4 trucks servicing the QC and RTG
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Straddle Carrier Move Order DIsplay
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Largest Maritime Customers Port of Hamburg, Germany Port of Antwerp, Belgium Port of Le Havre, France Port of Marseille, France Port of Los Angeles / Long Beach, U.S. Port of New York/New Jersey Port of Oakland, U.S. Port of Tacoma, U.S. Port of Durban, South Africa Port of Colombo, Sri Lanka 66
Local Installations ML2000—Int’l Union of Operating Eng. (IUOE) z z z z z
Local 406—New Orleans, LA* Local 178—Fort Worth, TX Local 487—Miami, FL Local 181—Henderson, KY Southern Apprenticeship Training—Iuka, MS
ML2000—U.S. Naval Reserves z z z z z z
NCHB 13—Gulfport, MS NCHB 12—Bessemer, AL NCHB 11—Jacksonville, FL NCHB 4—Charleston, SC NCHB 9—Columbus, OH NCHB 1—Williamsburg, VA
ML4000—U.S. Army T-School Ft. Eustis, VA ML4000/5000 N.Y. Shipping Ass.—Port Elizabeth NJ 67
Custom Experience Aviation Training Systems z
z
z
z
z
z
US Navy SH-2G Helicopter WST Development Program US Navy SH-60B/SH-60F WST Upgrade Program USMC CH-46E/HH-46D OFT Upgrade Program USMC AH-1W WST Upgrade Program Pilot Communication & Navigation Training System S-3 Aircraft Weapon System Trainer
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F-14D WST Upgrade Program
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F-15D/E Maintenance Trainer
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Custom Experience (Cont) Maritime Training Systems z
US Coast Guard Z-Drive Ship Control Training System
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US Coast Guard Buoy Tender Integrated Ship Bridge Control Training System (ISCTS)
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US Navy Barge Ferry Training System
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US Army Dock Gantry/Ship Pedestal Crane Trainer • Full-Size & Portable
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US Army Barge Derrick Crane Training System
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Driver Training Systems HyperDrive™ Authoring Suite
Vection™ Driving Simulators
• Creates Virtual Environment
• Vehicle Cab, Dynamics
• Standard & Customizable Drop&-Drag Tiles
• Virtual Driving Environment • Image Generator(s) and Display System
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Driver Training Systems (Cont)
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Select Customers (Custom) Military
DriveSafety
U.S. Army
General Motors
U.S. Navy
Ford
U.S. Air Force
Motorola
U.S. Coast Guard
Batelle Stanford U. of Michigan U. of Iowa
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Deliverable System Includes z
All Trainer Hardware and Software (Executable only)
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Factory Acceptance Test and Site Acceptance Test
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Installation at User Facility
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Train the Trainer Course (Up to 8 Individuals)
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One (1) Year Warranty
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After Delivery Support. Including: ¤ ¤ ¤ ¤
Hardware Maintenance and Repair Software Trouble Shooting Software Updates Training Support
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Trainer Support Requirements z
Operational Personnel Requirements ¤ No Dedicated Operational Personnel are Required ¤ Instructors Operate Training System ¤ Non Simulator Training Requires 1 Instructor to 1 Student ¤ We Recommend 1 Instructor per 3 Students
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Maintenance Personnel Requirements ¤ No Dedicated Maintenance Personnel are Required ¤ Part-time Maintenance Support
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Maintenance Support & Upgrade Program (MSUP) ¤ Full Hardware Repair Support ¤ Annual Preventative Maintenance ¤ Annual Software Updates
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GLOBALSIM BACKGROUND
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Company History Company Started in 1993 Acquired by Kongsberg Maritime (Norway) in February 2008 Headquarters in Salt Lake City, Utah, USA
Delivered Systems Worldwide GlobalSim is a Simulation Engineering Company Average Engineer Simulation Experience – 19 Years Expertise Includes: z z z z
Fixed Wing and Rotor Wing Aircraft Simulation MasterLift™ Product Line (108 Systems Delivered) Custom Simulator Design and Development Driving Simulation (48 Systems Delivered)
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Organization
GlobalSim
Custom Simulator Development
MasterLift Training Systems
MasterLift Crane Simulation Accounts for >50% of GlobalSim’s overall Business
Driver Training Services
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Capabilities Profile
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SUMMARY
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MasterLift™ Product Line
e g a t S
d
i n i a Tr
m u u n i t n o C g n
Hands-on Training Integrated Training
Entry/Basic Training 80
The Simulation Advantage Classroom + Simulator + OJT y y y y y y
Improved Instructor - Trainee Ratio Realistic Training Experience in a Controlled Environment Reduced equipment and logistical cost, reduced training time Non-Threatening Environment for Emergency Action Training Repetitive/Objective Training Capability Crawl (Class Room), Walk (Simulator), Run (OJT) Training Process
Result : More Fully Trained Operators
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Summary •
Simulation Training has been Around Since WWII
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Measurable Results from the Use of Simulator Aided Training: o Increased Productivity o Increased Safety o Decreased Liability o Increased Skills
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Technology Breakthroughs have Enabled High Fidelity Training Systems at an Affordable Price
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Actual Experience Show that Simulation Aided Training is the Best Solution Available to Provide Qualified Crane Operators
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GlobalSim Provides the Best and Most Cost Effective Crane Training Simulators Available in the Market Today
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Results of Improper Training (Cont.)
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Simulator Return on Investment Simulator Induced Effects
Areas of Cost Savings
Decrease training time on live equipment 60%
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Decreased overall training time 20%
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Decreased New Operator accident rates 45%
Increased efficiency during first 30 days.
Improve Instructor/ student ratio from 1:1 to 1:2-3
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Crane operating cost savings
New Berth Case Study Case Study Case Study Example For:
2x as •••• Most overlooked Total HR operators expense =are Salary, 3First-year - 4commonly STS Gantry Cranes an accident •• Intermodal demand is taxes, &cause benefits 9likely – 12toRTG cranes than operators with 1 yr Accident & 24 training shifts • • outpacing Usually 3supply shifts; orare 3> roughly experience • Ifoperators crews areper unmanned, what equivalent to crane 1 month’s HR is insurance cost Trainers agree that an cost in lost revenue expenses savings •• the 36 to 48ofnew operators operator’s first 200 hrs pose Beach)? • (LA/Long 1:1 training also includes the need training greatest risk to expensive If the lack of well operators trainers HRtrained expenses The U.S. •Army reduced • Training usually requires Human resources st year and isequipment a damming factor, how much • has 1 reduced Berth with 36employees. new crane among 1 Portaccidents of Antwerp 24 to 30 shifts; A single Antwerp instructor can costs savings Hamburg's limited access live • time GlobalSim’s technology revenue canto be realized by operators training 24 shifts operators by 45%. overall training by >20% • 36 operators X 24 Shifts X effectively work with multiple training cranesfilling was by to 1:1 allows operators gain vacant equipment 20% on remedied live equipment = 72 students and outside the 8experience hours =which 6,212 crane hrs. The Army inside also conducted aHR GlobalSim’s technology, in ahas nonfaster? months of expenses Opportunitysimulator cost • • showing STS crane with 60% formal study aof more currently replaced 60% their need threatening environment • How much revenue Improving ratio to 1:2 + can 20% savings simulator-trained operator utilization = 5,250 hrs ($1 for real cranes.bewhen an operator’s risk is = realized by more productive reduction in training time completing a complex maneuver million / year) greatest. operators in their 30 daysof cost savings of first 28 months 4x faster thanof a HR veteran operator 84 employment? related expenses.
Crane Models Ship-to-Shore Cranes z z z z z z
Reggiane Kone Paceco Nelcon ZPMC Liebherr
Jib & Jib-Boom Cranes z z
Gottwald Potain
Portainer Cranes (RTG & RMG) z
ZPMC
z
Morris
z
Kone
Pedestal Cranes z
Hagglund
Ship Gantry Cranes z
Morgan
Straddle Carrier MHE z z
Kalmar Noell
Reach Stacker MHE z
Kalmar
Construction Cranes z
Manitowoc (Mobile Lattice)
z
Link Belt (Hydraulic Telescopic) 85
