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First Quantum Minerals Ltd (FQM), a Canadian-based mining and metals company, has outfitted its Zambian, Kansanshi copper-gold mine with two of ThoroughTec’s latest generation CYBERMINE 5 Full-Mission simulators – and they could not be happier.

In 2017, FQM undertook to revamp their Mobile Equipment Operator training program and part of this included the utilisation of simulators – enter Ian McIntosh, Training and Development Manager at FQM. McIntosh said, “We looked at simulators and realised their unique potential to prepare our operators for emergency scenarios and situations.” And having had experience with simulation before, he knew the benefits the company and staff could all reap.

FQM conducted a thorough review of the market and after comparing all leading suppliers in terms of cost, features, potential for customisation, and support, it was clear that ThoroughTec Simulation, from South Africa, was the standout supplier to meet their needs.

FQM’s CYBERMINE 5th Generation Simulator System incorporates two ruggedised, containerised Base Units and three modular cabs, the Caterpillar 785-C, Hitachi EH3500 and Liebherr 9350. The simulators will be utilised heavily to train new recruits from the local community as well as refresher training for existing operators; every six months in the case of Hitachi truck drivers and once a year for the Caterpillar 785-C and Liebherr 9350 operators. “Having the simulators to handle the bulk of the training requirement, saves us from removing machines from production and considering the number of operators we have it adds up quickly. We also have the ability to better prepare our operators for potential equipment failures – the WHAT IF scenarios.” says McIntosh.

“Going back to the catalyst of purchasing the simulators. When we started the process, I revamped the whole training system, including the processes and procedures on site. I looked at the Airline industry for inspiration, and if you look at their training methods, they put a huge emphasis on simulator training for their pilots. The airline industry has a program called Upset, Prevention and Response (UPRT) which takes pilots through emergency scenarios over-and-over again until they do it the right way and it almost becomes muscle memory. I wanted to mimic that in our simulator training process.” ThoroughTec’s simulators allow operators to experience and practice responding to emergencies such as brake failures and vehicle fires, something that is impossible to do any other way!

Kansanshi Mine operates six trolley-assist lines on the pit ramps, with significant operational benefits including reduced fuel consumption, increased engine life and greater up-ramp speed, from 11kmph to 23kmph. To ensure that their truck drivers are proficient in the use of the trolley lines and thereby achieve their haulage-boosting potential, Kansanshi opted to include a custom Own Mine World in their simulator development. This ‘digital-twin’ of their mine site and operations gives trainee truck drivers the ability to practise using the pantograph system on their trucks, engaging and disengaging the trolley-assist lines at the ideal location and angle; and thereby avoiding mishap and inefficiency.

Another feature McIntosh saw and requested, following a tour of ThoroughTec’s factory, was the ability to network two or more simulator units – a common practice in the military simulation space. “I wanted the simulators to interplay, to train operators in teamwork and to provide them with a better understanding of how their actions affect the other operator.” notes McIntosh.

About ThoroughTec Simulation:

ThoroughTec Simulation has been designing advanced, hi-fidelity training simulators for over twenty years, during which time, the company has grown into one of the world’s leading training technology organizations, supplying the mining, military, construction and fire & rescue sectors.

In the mining sector, ThoroughTec is the only ISO9001 supplier in this highly specialized industry, applying MIL-STD engineering practices to its CYBERMINE range of simulators, which cater to both surface and underground mechanized operations.  Through their partnerships with some of the largest mining companies and training institutions in the world, ThoroughTec has established themselves as the leading supplier in the industry, deploying hundreds of simulators around the globe.

Notably, ThoroughTec’s portfolio of off-the-shelf products is now the largest on the market, representing almost 200 unique equipment models across the full spectrum of mechanised mining machines, from all the major OEMs.

Beyond simulation, ThoroughTec’s development team continues to innovate and in recent years their efforts have focused on providing turnkey workforce optimization solutions to the mining sector, culminating in their revolutionary, Workforce Excellence or “WX” Training Management and Operator Analytics Platform.

With all products developed and manufactured in-house, clients are assured of organic compatibility and harmonized support. Indeed, CYBERMINE products are renowned for their industry leading reliability and exceptionally low cost of ownership.

ThoroughTec’s state-of-the-art R&D and production headquarters are in Durban, South Africa, with satellite sales and support offices located in Perth, Santiago, Toronto, Salt Lake City, Moscow and Shanghai, to service all the major mining markets.

For further information, contact:

Andre Mendes | General Manager: North America

ThoroughTec Simulation

Tel: +1 289 291 3955

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