SIMOND is a corrugated board machine driving simulator, the result of collaboration between several key players. Initially developed by IRFIP (now IPC FORMATION), the simulator was upgraded in 2022 by IPC FORMATION and DS SMITH Packaging, under the impetus of Olivier DUTORDOIR (Training Coordinator Training Coordinator in Operations Technical Excellence Team at DS Smith.
Key updates include the addition of a single-face feature and more comprehensive heating tables. CORYS integrated these enhancements into the simulator on their platform.
Introduction to the Corrugator Simulator
This simulator works with physical licenses or on the cloud, and can be used to train corrugator operators using one hundred setting parameters and fifty quality defects.
Use of the SIMOND simulator at IPC FORMATION
For Trainers
The SIMOND simulator is a powerful teaching tool that reproduces realistic working conditions without the risks associated with direct handling of machines. Thanks to its multiple setting parameters and numerous failure scenarios, trainers can :
- Customize training scenarios: by creating specific exercises that simulate real production situations, trainers can adjust the parameters to suit different skill levels.
- Evaluate in real time: the simulator enables instant evaluation of trainees’ reactions and skills when faced with common and complex problems, facilitating immediate and constructive feedback.
- Increase efficiency: trainers can prepare exercises that can be reused and shared between them, reducing preparation time and maximizing the time spent in direct interaction with trainees.
For Trainees
For trainees, the SIMOND simulator is an opportunity to acquire and perfect their skills in a controlled, risk-free environment. The benefits for trainees are numerous:
- Immersive, hands-on learning: trainees can understand and master the complex processes of corrugator operation without the constraints and hazards of a real production environment.
- Improved technical skills: exercises cover a wide range of faults and set-ups, enabling trainees to develop fault analysis and problem-solving skills.
- Preparation for real-life situations: thanks to realistic and varied scenarios, trainees are better prepared to deal with real-life production situations, which can lead to greater comfort at their workstation and better performance in the field.
- Ongoing assessment and feedback: the simulator enables trainees to receive ongoing assessment and immediate feedback, facilitating a clear understanding of their strengths and areas for improvement.
Action Plan
An action plan has been underway since 2023 to reactivate and develop the use of the SIMOND simulator in training:
IPC FORMATION now has 10 reactivated and updated licenses.
6 trainers from the IPC FORMATION network have been trained to use the simulator and create exercises. They can now use it nationwide for skill development actions in corrugated board production.
A maintenance and support service are in place to ensure quick responses to trainers’ questions and any technical issues.
Operational Exercises
15 exercises are already operational for problem-solving on corrugators
Examples of Defects Addressed:
- Crystallized glue in SF1
- White glue
- High ST warping
- Low flute and high warping
- Crushed flute, low warping
- Honeycomb white glue
- Crystallized glue, high warping
- Upward warping
- Low flute warping
- Fold direction sense cover SF1
Examples of Adjustments:
- Act on cover embossing (-)
- Lower gel point of DF gluers
- Reduce DF heating or increase SF1 web heating
- Act on DF cover heating (-) and SF2 web glue
- Reduce heating belt load and glue
- Reduce table heating
- Act on DF preheaters (-) or SF web (+)
- Reduce SF1 glue film
- Reduce brake tightening
In summary, the SIMOND simulator is a highly effective tool for enhancing trainee skills, helping to ensure optimum training and preparation for work in the cardboard industry.
For more information: contact.formation@unidis.fr
Originally published in French by ZEH Solution on Observatoire de l’Industrie Papier Carton
