Utilizing TWI , a four-step training method developed during WWII and used extensively at Toyota and elsewhere , the paint process was broken down into its base elements and step-by-step exercises were developed for use within the VirtualPaint simulator training . A paint SME was identified to work with a VirtualPaint technical consultant . The simulator software was loaded with technical data and paint specifications that matched the aerospace coatings being sprayed at Skills Inc . A job breakdown allowed a scripted set of teaching points to be developed .
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Paint Supervisor , Ben Schubert , leads prospective painters through the paint simulation process . First , he demonstrates the painting process . He then clearly describes the key paint practices that he is following . He allows the student to try the process and get familiar with the equipment and practice spraying paint while restating the key points – with a focus on anything that makes the process safer , easier , or more efficient . Finally , he provides the “ why ” for each best practice . For example , students are instructed to spray from the top of a part to the bottom , not the other way around , to avoid debris ( FOD ) from falling on the component . Spray patterns and spray gun triggering are done a specific way to increase transfer efficiency . The VirtualPaint simulator software has four different simulations with spraying requirements associated with different part configurations becoming progressively more difficult at each level .
Today , paint supervisors and others at Skills Inc . are using the VR paint simulator to assess new painter applicants . Utilizing the simulator is now part of the interview process for painters who have stated they have prior experience . The system is also being used to standardize painter practices and train all new painters as well as upskill painters that want to take on more difficult components . New painter proficiency is being achieved in weeks instead of months ; nonconformances are beginning to drop and paint use is starting to shrink as painters are managing their transfer efficiency with greater proficiency . Painters that may be struggling are provided an opportunity to refine their paint spraying skills in a safe and supportive virtual reality paint environment .
An added bonus to having the paint simulator technology is the excitement and impact on generation Z students . As a nonprofit aimed at promoting aerospace manufacturing at local high schools , Skills Inc . provides frequent tours of its facility . One of the major highlights of a high school tour is now the VR paint simulator . When the supervisor giving the tour asks if anyone wants to put on the headset and try painting a 3D part in the simulator - all hands go up !
OCTOBER | NOVEMBER 2023 ISSUE NO . 35 51