Transcript generic template - Victoria University, Australia

The Virtual Powder Plant
Operator Training Simulator
for
Milk Powder Production
Processes
Michael Robinson – Manager, NCDEA Gilbert Chandler Centre
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Project sponsors
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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
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Reference:
Dairy Australia; ABARE
Powder Manufacturing Systems
• Large, complex and
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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
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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
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The typical Operator interface – Murray
Goulburn Cooperative Ltd Rochester site
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Focus: Operations &
Supervisory Staff
• Improved understanding of the plant
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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)
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Learner interface – evaporator simulator and operation procedure
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Learner interface – dryer simulator and operation procedure
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Outcomes: Delivery
• Class Usage
 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
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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
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Future developments
• Interface simplification
• Parent plant layout with core
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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
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