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training Blended Learning A more effective model for haul-truck operator training BY CHUCK FREY Too often, haul truck operator trainees don't retain enough of the knowledge they learn during training. This can lead to longer on-boarding cycles, lower productivity and potential safety problems in the mine. Blended learning, a technique that provides training via multiple modalities using a highly structured, building-block approach, has shown a lot of promise in addressing this challenge. Insights gathered over a threeyear period from mines in North America readily support this notion. In recent years, a number of trends have converged that are creating major challenges for mines worldwide. Experienced operators are retiring, taking with them a wealth of operating experience and knowledge. Fewer qualified candidates are available to replace them. As mining companies look farther afield for new operators, they find a growing percentage of new haul-truck operator trainees have no previous experience operating heavy machinery. Driving a haul truck is often an entrylevel position in many mining operations. As such, it presents a real opportunity to set the stage for a safety culture and inculcate new operators into a safety-first mentality. Computer-based training alone is not an effective method for training equipment operators. Because a large amount of knowledge is transferred to trainees in the form of a "mind dump," they have difficulty retaining what they have learned when they transition to field training. That, in turn, can lead to longer on-boarding cycles, as well as procedure and safety concerns. Field training at many mines isn't as structured as it needs to be. Typically, haul-truck operator trainees ride along with experienced operators for a prescribed number of hours. This approach is intended to give trainees practice operating a haul truck on a supervised 30 www.coalage.com basis. It's also an ideal opportunity for trainees to observe experienced operators in action, so they can model their work practices. But all too often, it's up to the experienced operator to decide how much, or how little, knowledge is conveyed during these ride-alongs. At best, operator training is inconsistent; in the worst case, bad habits or inaccurate and unsafe practices are passed on to the new hire, which are difficult to correct. In many mines, checklists are used to assess whether a trainee is ready to begin independent operation. But too often, they are brief and superficial — and don't serve as accurate indicators of a trainee's readiness for independent operation. When they are operating in a production loop with other haul trucks, these "weak links" can slow down everyone else, causing a significant drain on a mine's productivity. Haul-truck operator training in many mines is very equipment focused. Trainees learn about operator controls, how to conduct a pre-use inspection, and learn far less about how to perform critical tasks safely and efficiently. Trainees never get a sense of the bigger picture — how the work they perform contributes to the bottom line of the mine, or how to interact effectively with other equipment operators and the mine's dispatcher. These represent significant, unrealized opportunities for performance and productivity improvement at many mines. How Inadequate Training Creates Operational Challenges Operational challenges often increase when the new operator's initial training is inadequate. Typical operational problems with haul trucks include speeding on grades, overuse of service brakes, incidents with shovel counterweights, speeding in unsafe weather conditions, and increased truck maintenance due to operators not monitoring gauges and not operating the truck within proper parameters. These improper operating practices tend to shorten component and truck life, can cause unplanned truck downtime and may result in near hits and incidents. Too often, mine trainers address these improper operating practices after trainees become production haul truck operators. A more effective approach is to modify training methods to produce better outcomes from the start. A potential solution to this is blended learning. Blended learning holds signifi- December 2013