Process Simulation Software for the Plastics Industry

Affordable and complete process simulators are now available. PICAT, from PolymerTraining – formerly known as BPTA (British Polymers Training Associates), provides functionality previously found only in expensive, proprietary process simulation software. These programs allow the user to experience a ‘real’ processing environment minus the monetary and time costs involved in interrupted production and material waste. Using realistic graphics within preset processing scenarios, the program measures the user's application of skills. Participants are required to ‘produce’ an acceptable product within specifications – utilizing interactive process control parameters to identify and remedy product faults and potential faults. Troubleshooting abilities are measured and logged as a hard copy spreadsheet for the facilitator to analyze.

Assessments

The simulator is designed to respond in the same way as a real machine. Assessments are set up with defects in a plastic product. The severity of the fault is indicated by an index number; the bigger the number, the worse the fault. The participant adjusts the machine controls until the fault is cured and the product is within desired specifications. Any process changes are reflected as in real life. As changes are made, the time is recorded and the amount of rejects accumulates until the defect or machine can produce a repeatable process. As with any process, one defect may be corrected only to create another problem – just like in the real world. All of the participant's actions are recorded in a database so that the facilitator can assess strengths and weaknesses in a database that is password protected. Built in exercises can be prescribed by the facilitator to work on specific areas of weaknesses for each participant. The facilitator can also set up new problems to suit any special training needs.

In the end, people will always have to work on the real thing. The PICAT simulator programs are about getting to that final stage as beneficially as possible. Learning this way on the computer is quicker, cleaner, safer, and infinitely cheaper than making scrap on costly machines.