High Volume Training in a Risk Rich Environment
BHP operates Escondida, the largest copper mine in the world, located in northern Chile. With approximately 12,000 workers, safety and operator competency are core concerns. BHP supports CEIM, a regional trade school that trains operators and apprentices in equipment operation and safety in BHP's training protocols which are globally recognized as the highest in the industry.
In 2014, EXO was asked to develop a training simulation program for boom truck operations and tasked with addressing several challenges that CEIM faced when training with real equipment, namely:
- The inability to simulate hazards and accidents
- The inability to provide different scenarios
- Create a training up to BHP's standards
- Limited availability and cost of renting trucks for classes
- Difficulty of meeting student demand, as there were no available simulators
- Standard testing for every trainee
How did we achieve that?
After the deployment of the EXO solution, these were the top results:
- The first year, 1,200+ workers used the simulator with 4,500 simulation sessions completed
- Trainees achieved a 44.9% average increase in training performance improvement over 3 sessions
- Most important, annual third-party data revealed that an increase in errors directly corresponded with a 50% decrease of actual work site safety incidents and improved machinery usage
How We Created A Holistic Approach to Design and Implementation
- Assessed existing training curriculum and methodology to come up with recommendations for enhancements to achieve challenge goals
- Incorporated preparatory classroom component into the training simulation design
- Established a new 4-step simulation process that accounts for all operator requirements for the mining industry: Personal Safety, Environment Safety, Equipment Safety and Operation
- Developed multiple new, site-specific operational scenarios with increasing levels of difficulty and various hazard risks. Defined and implemented standard and biometric indicators to validate individual and program performance
- Conducted user experience research, onsite system testing, instructor training, and provided support during program rollout
EXO Training Benefits
- Immediate and memorable application of classroom concepts
- Impactful first contact with operation
- Enhanced readiness via simulated risks, failures, and accidents
- Consistent evaluation criteria with verified reporting
EXO Safety and Financial Benefits
- Certification processes filter only suitable candidates as the simulator allows early detection of knowledge gaps
- Accidents and work site downtime reduced
- Operator error and work site incidents reduced
- Machine damage and maintenance costs down
- Machine availability increased
The Profitable Error
A study developed in Australia in 2011, generated a side by side comparison of simulator errors and real life operation errors, generating the first concrete proof that errors in simulation will turn out a profit in operation.
About EXO Insights
EXO Insights helps global companies unlock the full performance potential of their workforce in high-risk, mission-critical environments where safety and precision are top priorities, using advanced AR/VR systems. EXO Insights measures the “how” of work, allowing workers and training leaders to improve their knowledge and work capacity. Our EXO Biometric solution transforms and builds on existing industrial safety and training standards to move organizations past traditional training methods.
© The brand, logo and other visual assets related to BHP are the property of the BHP Billiton company and used here uniquely to illustrate the article.
