Debates about the close integration between technology and workers are ongoing. However, in the training sector of the safety industry, the two are getting along just fine.
The key to this happy relationship is based on the increased processing power of emerging technologies, which enable more lifelike simulations. These simulations of job tasks help workers master the skills necessary to properly perform the job before the actual work begins, thus preventing injuries.
Pushing the envelope further, machines are being outfitted with technology that is able to determine if proper training methods are being implemented and then being able to act upon that data.
Let’s start with virtual reality, which is catching on quickly as hardware has improved and prices have decreased. Virtual reality (VR) creates a simulated three-dimensional environment that allows users to interact with it, using a headset, which makes the situation feel real. “We introduced virtual reality around eight years ago, as we needed to accelerate training and onboard operators quickly,” says Shannon Curtis, senior manager technology solutions and marketing at the Raymond Corporation, a manufacturer of lift trucks and material handling vehicles. “It has been very well-received and successful.”
New methods of training are being adopted as both the jobs and makeup of the workforce are shifting. “The field has changed,” notes Curtis. “I explain it this way: Instead of steel-toe shoes, people are now working in tennis shoes and shorts. The environment has changed and involves e-commerce and light picking, so we are seeing different demographics of people who are entering the field. For example, we have more people who are working second and third shifts while going to school.”
Many of these new employees do not have prior experience in warehouses so ensuring that they are properly trained in their first year is essential. OSHA has reported that new employees are five times more likely to get injured than more seasoned workers.
“When it comes to manufacturing and warehousing, you’re dealing with high-risk, technical roles where long ramp-up times and safety issues just aren’t an option,” explains Nick Day, vice president of sales and client solutions at Roundtable Learning, an immersive education company. “XR [extended reality, which includes VR] gives teams a hands-on way to train without slowing down operations or putting anyone in harm’s way. It’s faster, safer and significantly more cost-effective.”
Gina Godeen, a former safety manager in the construction, mining and manufacturing industries, and now an editor at J.J. Keller & Associates Inc., a provider of safety and compliance solutions, has found that to be true. “Hands-on training coupled with visual training is more effective, especially being able to demonstrate hazards in a controlled environment,” she says. “This is especially important in confined spaces and lockout/tagout training.”
Training Built into Machines
Moving technology to machinery is the next step in safety training. The machinery is equipped with technology that can reinforce training by alerting operators to safety protocols. And even more importantly, the machine can take an active role if proper operating steps are not present.
One example is that of tethering. Raymond has designed an integrated wireless solution that limits a lift truck operation if a proper connection is not detected between a self-retracting lanyard and an operator’s harness. “This technology can make sure that operators don’t forget to tether,” says Curtis. “With increased pressure on productivity, an operator might forget this step. The machine is programmed to detect this and will issue visual and audio warnings. After that, if the harness is not properly connected, the lift truck will limit travel speed and disable lift capability.”
Another technology Raymond is using, which was designed to reinforce operator training, is an object detection system that issues both audible and visual notifications of objects within a lift truck’s travel path. When an object is sensed, using LiDAR technology, lift trucks can be brought to a controlled slowdown or stop, in or outside the aisle, consistent with the facility’s rules.
“This machine-assist technology makes sure that a worker can’t have a mishap,” says Curtis. “From the data we receive from the machine, we can spot behavior. For example, if a lift truck is making frequent stops, it could mean that the operator needs to be retrained, or the area could be too congested, and a new layout is necessary.”
Forklift safety is a major concern for manufacturing companies. In fact, one of the largest U.S. retailers approached Roundtable Learning for assistance in improving forklift safety within their facilities. The company was seeing an increase in the number or recordable incidents and even a death.
Part of the problem was the high rate of turnover, which puts a strain on training. “Using VR, new employees could become proficient at the task prior to ever stepping on a forklift,” says Day.
And as Raymond found, the data from this retailer’s training allowed for further analysis. “We can now take advantage of trends that we are seeing based on the data we gather. For this retailer, we did a common trend analysis to find out what the facilities were getting wrong and doing right, and we couldn’t have done in the past. That’s a huge win to have that level of insight.”
VR’s Unusual Training Ability
In most industries, but especially in manufacturing and logistics, new employees are not always sure what their job entails, and this often leads to high turnover. Having a way to demonstrate the job requirements prior to accepting a position is a valuable tool that VR offers.
“We have customers that use VR as a pre-screen,” explains Curtis. “Training and onboarding are the most expensive parts of bringing someone into a company. To provide training and then not have long-term employment is expensive. VR training minimizes this.”
And the expense of training is always an issue when companies determine their overall budget. “The next step for the safety industry is to find a way to break through the barrier of not prioritizing safety in the budget,” explains Godeen. “While technology and products have come a long way in our industry, there is still an issue with allocating the necessary resources for safety and having that safety-first mindset.”
But when companies have a safety-first mindset, employees appreciate it. “We recently rolled out a program for one of the largest online retailers, and our team was on site taking some seasoned folks through the training, and there was a gentleman who started tearing up seeing the evolution of training. He explained that now he would be able to show his colleagues what to do and why and keep them safe.”
