During these training sessions, employees had the opportunity to exercise automation sequences and contribute their own ideas and feedback. Many suggestions were integrated into the solution while at the test center. This approach enables them to assist in making improvements that will reduce the time to commission the systems on site. Training allows personnel to become familiar with the specific plant equipment and technology and understand the practical aspects of plant operation. The personnel can comprehend the sequence of operations, the flow of materials, and the interdependencies between different parts of the plant. Safety procedures are emphasized, ensuring all personnel are aware of safety protocols and emergency procedures. Additionally, personnel are taught how to identify, diagnose, and resolve common issues that may arise during the commissioning phase and later during regular operations.
Dave Durci, Senior Electrical Project Engineer at Aluminum Dynamics LLC, expresses his appreciation for the X-Pact® Plug & Work integration test: "I'm very impressed with the level of completeness that I find here. All the operator desks are set up and functional. More importantly, there is a simulator that runs against the mill control systems. This gives us a unique opportunity to exercise the software and to identify problems that could cause difficulty once we're on the site."
A team that has trained together in the integration test environment and has a shared understanding of the plant's operations can immediately contribute to an effective start-up, more efficiently, leading to smoother operations, improved equipment longevity, and reduced maintenance costs.
“The integration testing provided valuable insights and an opportunity to be proactive to address concerns ahead of starting up the equipment. Our time to start up and first coil, once all of this equipment is set up, will be minimized. I’m looking forward to commissioning of the plant!" Durci concludes.
Along with the operator training, Aluminum Dynamics also makes use of the training services offered by SMS TECademy. The special feature here is that SMS group’s coaches and experts teach from Germany or other SMS group locations worldwide while the customer’s participants sit in the U.S.A. and experience the training live. Virtual maintenance operations can be practiced before the real plant has been set up, which is an additional benefit to starting up a plant.
By investing in the training of their personnel, Aluminum Dynamics is positioning itself to achieve a successful commissioning and to maintain high operational standards throughout the lifecycle of the plant. This proactive approach to training and development is essential for maintaining a competitive edge in the industry.
This article is a summary of our Leading Partner Talk with Dave Durci and Blagoje Uscumlic at Aluminium 2024 trade fair. Sign in for SMS group #Connect and get access to all our Leading Partner Talks.