The PackSim simulator has proven to be an excellent tool for training both new and veteran press personnel. A multitude of defects can be simulated, and the exercises can be tailored to a higher or more basic skill level, depending on the class participants.

Learning to set up the simulator wasn’t difficult. Once the press parameters are set that enable the simulator to resemble a particular press, it takes only a matter of minutes to set up an exercise. Most of the work is done by pointing and clicking the mouse.

Four computers - simulators - are used for training, with one person per simulator. Pairing two people per simulator appears to work well when a less-experienced person is coupled with someone who is highly skilled. It normally takes about two hours for everyone to learn the locations and operations of the buttons, etc., but if the person is adept with a computer, this time can be reduced.

The biggest problem Westvaco encountered with the simulator was that some of their employees had never worked on a computer or operated a mouse. Even with that limitation, by the end of the day those same employees had learned the mouse and had become comfortable with the system.

Employees have really enjoyed working with the simulator and have remarked how much they liked it, comparing it to listening to a lecture or watching a video. One participant remarked that he "worked on" more defects in Westvaco’s eight-hour class than he would have in a month on the press.

One of the unexpected benefits of using the simulator is that instructors can spot weaknesses in individuals by letting each class go through a certain set of exercises. The rest of the class can then be tailored to that individual or group, depending on the weakness. This means that valuable time isn’t wasted covering material everyone already understands.

Westvaco is currently conducting "PackSim Challenge 2000" - the brainchild of Ed Davis. This is a competition to see which press crew is the best at troubleshooting by performing a set of exercises that the instructors have set up. The top four crews will receive prizes. The plan is to conduct this "challenge" each year.

Frank Watson Training Director Westvaco Corporation

Gravure, Summer 2000 Reproduced with Permission