Resurgence of Manufacturing Spotlights Need for Training
It’s no secret that the COVID-19 pandemic took a toll on manufacturing in America. Alongside nearly every other industry, manufacturing faced major challenges in 2020 and the years that followed, particularly with regard to supply chain problems.
Fortunately, the tide appears to be turning. In a recent Bloomberg article, authors Enda Curran and Katia Dmitrieva report that “[a]ssembly lines around the world are starting to hum again, marking a turn in a years-long manufacturing slump.” That’s good news here and abroad.
According to Curran and Dmitrieva, “[t]he nascent industrial recovery is led by the world’s two biggest economies. Chinese manufacturing has made a strong start to the year, boosting the economic outlook, and US factory activity unexpectedly expanded last month for the first time since September 2022, buoyed by rising new orders and a jump in production.”
Factory activity isn’t the only key indicator reflecting an uptick in American Manufacturing. The authors note that “JPMorgan/S&P Global’s manufacturing index notched a second month above expansionary territory in March and sits at the highest level since July 2022. If sustained, that’ll help catalyze a broader and stronger economic recovery that’s already spreading beyond the US.”
The recovery could be a bumpy ride. However, the authors believe there is reason for optimism: “While it’s still early days…the activity nonetheless marks a departure from the slowdown that took hold globally as consumer demand pivoted to spending more on services such as travel and dining out instead of buying more goods as pandemic-era restrictions ended.”
As American manufacturing ramps up during this period of recovery, manufacturers will still be faced with a labor pool that continues to have fewer highly skilled workers than employers need. Where will the workers come from? Until educational institutions expand the pipeline of skilled workers, manufacturers will have to pick up some of the slack of training workers with the skills they need to succeed.
Of course, not every manufacturer is prepared to train workers with the knowledge and hands-on skills they need to make an immediate impact in the workplace. Fortunately, employers don’t have to be training experts to launch an effective training program.
The experts at DAC Worldwide can help any manufacturer quickly and efficiently implement a training program that targets the specific skills workers need to be productive. For example, a thorough review of training systems is a great place to start. Do employees have access to hands-on training with actual components they’ll encounter on the job?
If not, partnering with established companies to provide industrial-quality training systems that will stand the test of time will help ensure a competent workforce. Be sure to check out DAC Worldwide’s variety of hands-on focused skills training systems that feature the real-world components workers will encounter in the field!
- Published in News
Foundational Electrical Skills Remain Essential in the Modern Industrial Workplace
Do you remember the good old days of the COVID-19 pandemic? Me neither. Empty store shelves devoid of your favorite products. Supply chain disruptions affecting every aspect of your modern life. No, those were not fun times.
Anyone shopping for a new or used vehicle during the pandemic probably remembers the lack of vehicle supply leading to huge price increases. In some cases, thousands of new vehicles sat in parking lots waiting for one tiny, but critical component—usually a semiconductor or “computer chip”—before they could be shipped to dealers for sale.
The fact that our auto industry relied almost exclusively on foreign suppliers for such key components did not go unnoticed by the federal government. In a recent IndustryWeek article, author Sarah Shinton notes that “[i]n 2022, the White House signed the CHIPS and Science Act into law, a bipartisan effort to increase domestic advanced semiconductor manufacturing. The legislation made a historic $52 billion investment in American semiconductor research, manufacturing and workforce development.”
Is your area one of those lucky enough to have acquired a new semiconductor manufacturing facility? If so, you may not have heard a lot about it yet. Shinton points out that “new projects are facing construction delays and permitting issues.”
More problematic, however, is the fact that there’s a larger issue looming: “the country might be unable to generate enough electricity to power new fabrication plants, leaving billions of dollars in federal funds stranded and one of its most critical supply chains vulnerable.”
Shinton notes that “[w]hile manufacturing semiconductors has always been energy-intensive, the process is becoming even more so as chips are developed to be smaller and more powerful. The most advanced semiconductors require extreme ultraviolet (EUV) lithography machines, which use ultraviolet light produced by rapid-fired lasers to burn fine details on silicon wafers.”
Unfortunately, “these machines consume 10 times as much power as earlier generations of equipment.” How much power is that? A lot. Shinton points out that “the Taiwan Semiconductor Manufacturing Company (TSMC), the world’s leading semiconductor manufacturer,…now consumes more electricity than some U.S. states.”
This presents a huge problem for future chip fabrication plants in the U.S. According to Shinton, “semiconductor manufacturing creates large pockets of demand in the areas where fabrication plants are located. A rapid increase in load presents challenges for grid operators who maintain the delicate balance between electricity supply and demand, preventing curtailments or worse, blackouts.”
The phasing out of coal-fired power plants in favor of alternative sources, such as natural gas, solar, and wind, could also be problematic. “The vast amount of electricity needed to onshore this new manufacturing comes at a time when America’s power grid is increasingly unreliable as the country undergoes rapid changes…many regulators are raising alarms that power plants are being retired faster than they are replaced, leaving the country at risk of electricity shortages.”
Moreover, “[t]hese mass retirements are also happening while electricity demand nationwide is increasing from data center growth, expansions in manufacturing and intensifying weather conditions…Over the past year, the five-year load growth forecast nearly doubled, jumping from 2.6% to 4.7%…Without expanding the high-capacity transmission system, our grid will struggle to meet this demand.”
What do these problems mean for the future workforce? Not only will dozens of semiconductor manufacturing facilities need highly skilled workers for their plants, but the industries supporting these new ventures will need thousands of workers with fundamental electrical skills as public utilities work together with industry to ensure a stable electrical grid for the future.
How do companies and schools train the next generation of professionals with the electrical skills they need to succeed in the modern workplace? A thorough review of training systems is a great place to start. Do employees and students have access to hands-on training with actual components they’ll encounter on the job?
If not, partnering with established companies to provide industrial-quality training systems that will stand the test of time will help ensure a competent workforce. Be sure to check out DAC Worldwide’s variety of hands-on electrical training systems that feature the real-world components workers will encounter in the field!
- Published in News
Electrical Safety Training Sets the Stage for a Secure Workplace
My neighbor asked me to install a new electrical outlet in his master bathroom. He was eventually shocked to learn that I’m not a licensed electrician! OK, that’s an old—and terrible—joke, but it does underscore the importance of safety when it comes to working with electrical current.
In the modern industrial workplace, there are a whole host of skills that workers need to know. No matter how highly skilled a worker might be, however, nothing will matter if the fundamental basics of safety aren’t mastered.
When it comes to safety, one of the most important skills that workers must learn is how to work safely with electricity. According to a FacilitiesNet article by Ashley Beebe, “[w]hen working with electrical distribution systems and components, frontline maintenance technicians and engineers often face the potential for serious injury or death from electrocution or arc flashes, but knowledge of safety tips, procedures, codes and regulations can help technicians and engineers lessen the risk and potential for serious injury or death.”
That’s why, “[a]ccording to the Occupational Safety and Health Administration (OSHA), employees must not work near an electric current, any equipment, or a part they may come in contact with while on the job, unless it has been de-energized. If an electric current has not been de-energized, employees must be protected by isolation, insulation, warning signs or other methods.”
In safety training, the control of hazardous energy is often known by its more popular moniker “lock-out/tag-out or LOTO.” According to OSHA, “[p]roper lock-out/tag-out practices and procedures safeguard workers from hazardous energy releases.” Teaching workers hands-on LOTO skills will help them to understand how to properly control hazardous energy and maintain a safe work environment.
For companies looking to improve their safety training, a thorough review of current training materials is a great place to start. Do employees have access to hands-on training with actual components they’ll encounter on the job? If not, partnering with established companies to provide industrial-quality training systems that will stand the test of time will help ensure the continued safety of the workforce.
For example, DAC Worldwide offers a safety training system specifically designed to give employees the hands-on experience they need to master lock-out/tag-out skills. Be sure to check out DAC Worldwide’s Lock-Out/Tag-Out Training System and contact a DAC Worldwide representative to learn how you can improve your training today!
- Published in News
Learn Essential Motor Control Skills with DAC Worldwide’s Hands-On Training Systems
Industrial machinery requires a wide variety of different types of motors to function efficiently and effectively. Whether they’re powering a compressor, pump, fan, or conveyor, three-phase induction motors keep operations at industrial facilities moving steadily.
Many induction motors require significant power given their heavy-duty applications. Moreover, they draw a high electrical current upon start-up. In fact, start-up current can sometimes be as much as 5-6 times what they draw at normal operating speed. This is why they require a special device called a motor starter.
If industrial motors relied solely on circuit breakers or fuses, those would trip or blow every time the motor started. That’s obviously unacceptable in an industrial setting. Instead, specialty motor starters start and stop induction motors using manual or automatic switches. They also protect motor circuits from excessive heat caused by overloads during normal operations.
Motor starters consist of two primary parts: (1) an electromagnetically operated set of contacts (called a contactor) starts and stops the motor by beginning or ending the flow of electrical current; and (2) an overload relay that protects the motor from drawing too much current and overheating.
Likewise, motor starters usually consist of two circuits: (1) a power circuit that transmits the primary voltage to the motor via the starter contacts and overload relay; and (2) a control circuit that manages the contactor coil that creates the electromagnetic field that operates the power contacts.
Because there are so many different types of industrial applications that require induction motors, there are likewise a wide variety of different types of motor starters. One common type is the reversing magnetic motor starter. Reversing starters, as their name implies, are specifically designed to efficiently reverse shaft rotation of a three-phase induction motor.
Reversing starters work by interchanging two contactors supplying electrical current to the motor, as well as having both a forward and a reverse starter. To ensure that only one of the starters can be engaged at any particular time, reversing starters feature both mechanical and electrical interlocks for enhanced safety.
Industrial maintenance technicians must be familiar with all sorts of induction motors and their motor starters. Hands-on training in electrical maintenance can elevate your technicians’ skills to the next level.
For example, if you want to ensure your maintenance technicians have the skills to work with reversing magnetic motor starters, DAC Worldwide’s 3-Phase Motor Control Training System with Magnetic Starter (423-000) offers comprehensive training in the operational principles, wiring, fault troubleshooting, and application of industrial three-phase, reversing magnetic motor starters.
The 3-Phase Motor Control Training System with Magnetic Starter is self-contained, allowing for individual study by a single student or a small student group. While often used independently, the training aid can be integrated with other optional products relating to programmable controllers, pilot devices, and motor-driven mechanical systems.
This electrical trainer includes a variety of industry-standard components, including: a three-phase induction motor; reversing magnetic motor starter with auxiliary contacts, mechanical and electrical interlocks, and overload relay; on-board wiring devices including Hand-Off-Auto (HOA) control station, manual control station, and automatic timer; color-coded, shielded banana-jack receptacles for all motor leads, supply connections, and control components; circuit breaker with lock-out/tag-out; keyed power switch; pilot light and emergency stop switch; and four instructor fault switches to create common component faults for troubleshooting instruction.
The 3-Phase Motor Control Training System with Magnetic Starter is only one of DAC Worldwide’s many electrical training systems. Visit DAC Worldwide online to learn more about other electrical training systems, such as the Three-Phase, Squirrel Cage Rotor, AC Motor Training System; 1-Phase Motor Control Training System with Manual Starter; DC Permanent Magnet Motor Control Training System; and many more!
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DAC Worldwide Offers AC Motor Training in a Compact, Convenient System
Today’s industrial facilities feature a wide array of different types of machines, from simple pumps to complex automated robots. One of the most common machines you’ll find in any industrial setting is the electric motor.
Simple, versatile, and available in many different configurations, electric motors carry the burden of converting electrical energy into mechanical energy. At the most basic level, electric motors can be distinguished based upon their power source: direct current (DC) or alternating current (AC).
For industrial use, the most common type of electric motor is the AC induction motor (also known as an asynchronous motor). The name “induction” is used because electrical current is induced in the rotor rather than supplied externally. The popularity of the AC induction motor stems from its simplicity, relatively low cost, and excellent reliability in a wide range of applications.
Induction motors can be further divided into two primary types: single-phase and three-phase, depending upon the type of electricity used to power them. The most-used electric motor throughout industry is arguably the three-phase squirrel cage induction motor.
Squirrel cage motors rely upon electromagnetic induction to create motion by converting electrical current into rotational energy. AC current travels through the stator, the stationary portion of the motor that consists of the housing and a series of windings (usually copper). The three-phase AC power energizes the windings, creating a rotating electromagnetic field.
The rotating part of the motor, known as the rotor, sits inside the stator. It contains a squirrel cage and bearings mounted to a stainless-steel shaft. The squirrel cage consists of circular end caps with rotor bars covered with steel laminations between them. The electromagnetic field generated by the stator fluctuates around the rotor, inducing opposing magnetic fields in the lamination-covered rotor bars, creating rotational motion.
The “squirrel cage” terminology comes from the fact that the rotor’s shape resembles a squirrel cage. If you haven’t seen many caged squirrels, then this may still cause some confusion. Apparently, long ago, squirrels were frequently kept as pets and would get exercise on a spinning wheel in their enclosure. Perhaps a more modern term for this type of rotor would be “hamster wheel” instead of “squirrel cage,” but we don’t expect the three-phase hamster wheel induction motor to catch on anytime soon.
Why is the three-phase squirrel cage induction motor so popular? It has quite a few advantages, including relatively low cost, ease of installation, high efficiency, low maintenance, and durability. These advantages are the reason that experts estimate that as many as 70% of industrial machines are driven by these motors today.
These popular induction motors can be found in just about every industrial setting you can imagine. Of course, they’re particularly useful in applications that require a low maintenance, constant-speed, low-torque motor that’s also self-starting, such as: machine tools (CNC and lathes); generators; fans and blowers; industrial drives; and centrifugal pumps.
It’s critical for any modern industrial maintenance technician to be thoroughly familiar with three-phase squirrel cage induction motors. How can educators and employers ensure that their workers possess the skills they need? DAC Worldwide offers a wide variety of electrical training systems specifically designed to give employees the hands-on experience they need to master different types of electrical motors, transformers, and more!
For example, DAC Worldwide’s Three-Phase, Squirrel Cage Rotor, AC Motor Training System (412-000) provides hands-on experience with a squirrel cage induction motor. Learners can use this training device to practice motor wiring by using banana jack receptacles on the control enclosure’s front panel face, study the motor’s construction, practice industrial motor maintenance skills by using fault insertion switches for hands-on troubleshooting training, and practice lock-out/tag-out (LOTO) procedures by using the system’s master circuit breaker.
DAC Worldwide’s training systems feature heavy-duty construction with real industrial equipment. Be sure to check out DAC Worldwide’s Electrical & Electronics Training Systems and contact a DAC Worldwide representative to learn how you can improve your training today!
- Published in News
DAC Worldwide Makes Industrial Maintenance Training Easy!
Industrial maintenance training for technicians in the oil and gas and petrochemical industries must teach them fundamental knowledge of and hands-on skills related to a wide variety of different types of valves that keep fluids flowing through vast networks of piping.
For example, different types of check valves help to prevent the reversal of fluid flow in piping systems. One specific check valve — the piston check valve — can often be found in systems that experience frequent changes in fluid flow direction.
Maintenance technicians will find piston check valves in all sorts of common applications, including: water, steam, and air systems; feed water control in nuclear facilities and steam power generation plants; freshwater supply; wastewater treatment; monitoring and sampling systems; dump lines; food and beverage processing; air conditioning systems; and pharmaceuticals and chemicals manufacturing.
Piston check valves contain a dash-pot with a cylinder and weighted piston or disc. These valves are activated by fluid flowing through a system. The pressure of the flowing fluid opens the valve, which allows unobstructed flow in one direction while fluid flow pressure remains constant.
When pressure decreases as fluid flow slows or reverses, gravity forces the piston to close the valve, preventing backflow. While piston check valves primarily rely upon gravity, the weight of the piston, and back pressure to force closure of the valve, some models also incorporate springs to assist with valve closure.
Piston check valves are popular because of their many advantages, including: durability; versatility; repairability; cost-effectiveness; efficiency; and ease of installation, maintenance, and repair. However, piston check valves are not suitable for applications requiring bi-directional fluid flow or pulsation fluid flow.
If you want to ensure your maintenance technicians have the skills to work with piston check valves, DAC Worldwide’s Piston Check Valve Cutaway (295-706) provides valuable classroom training in the operation, construction, and maintenance of industrial piston-type check valves.
DAC Worldwide’s valve cutaways use actual industrial valves that have been carefully sectioned and color-coded to expose and showcase the complete internal configuration of the valve. Seal features and hardware locations are retained, allowing for “hands-on” training in maintenance.
Moreover, common valve makes and models are chosen to ensure industrial relevancy. All cleaning, priming, and painting uses a high-durability urethane coating to ensure this training tool will last for years.
DAC Worldwide’s Piston Check Valve Cutaway features a welded-bonnet, socket-welded valve exactly like those commonly used in high pressure oil & gas production applications, providing unparalleled training to those involved in oil & gas production operations and maintenance training.
The Piston Check Valve Cutaway is only one of DAC Worldwide’s many oil and gas training cutaways. Visit DAC Worldwide online to learn more about other oil and gas training tools, such as the Diaphragm Dump Valve Cutaway, Oilfield Backpressure Regulator Cutaway, and many more!
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Safety Leaders Reveal Most Significant Challenges in the Workplace
What would you consider to be the most foundational skillset in the industrial workplace? If you did not answer “safety,” there are safety leaders everywhere who would like a word with you. In fact, you may be part of the problem!
Safety leaders are tasked with making sure the industrial workplace is as safe as possible for workers. There’s no greater threat to industrial efficiency and productivity than workplace accidents that injure workers and cause costly delays and downtime.
As more and more advanced automation technologies enter the workplace, safety leaders constantly face new challenges to keep workers safe as they work alongside new machinery. But safety shouldn’t just be the concern of a few leaders. All employees need to make safety a top priority.
According to a recent EHS Today article by Dave Blanchard and Nicole Stempak, “EHS Today’s National Safety and Salary Survey 2023 invited respondents (all of them EHS professionals) to share comments regarding their job situation, the safety profession, and the biggest professional challenges that they face.” Here are some of the top challenges identified by the nation’s safety leaders:
- Finding qualified employees
- The transition from a human-based workforce to a technology-based workforce
- Safety buy-in from the younger workforce
- Senior leadership buy-in
- Mental well-being
- Too many rules and regulations
- Profit over safety
- Training and job knowledge
- Employee turnover
- Older supervisors are retiring faster than we can train replacements to take their place
- Employee complacency
- Doing too much too fast
- Finding employees with the proper skillsets
- Keeping the workforce actively engaged in their own safety
As you can see, safety leaders face a wide variety of challenges in the modern industrial workplace. What can be done to improve a workplace’s safety culture? How can leaders influence others to prioritize safety, leading to fewer accidents? One solution is to implement a quality safety program that teachers workers the knowledge and skills they need to stay safe in the workplace.
One of the most basic—and important—areas to focus on is the control of hazardous energy, often known by its more popular moniker “lock-out/tag-out or LOTO.” According to the United States Department of Labor’s Occupational Safety and Health Administration (OSHA), “[e]nergy sources including electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other sources in machines and equipment can be hazardous to workers. During the servicing and maintenance of machines and equipment, the unexpected startup or release of stored energy can result in serious injury or death to workers.”
“Workers servicing or maintaining machines or equipment may be seriously injured or killed if hazardous energy is not properly controlled…Injuries may include electrocution, burns, crushing, cutting, lacerating, amputating, or fracturing body parts… Craft workers, electricians, machine operators, and laborers are among the millions of workers who service equipment routinely and face the greatest risk of injury.”
Fortunately, “[p]roper lock-out/tag-out practices and procedures safeguard workers from hazardous energy releases.” Teaching workers hands-on LOTO skills will help them to understand how to properly control hazardous energy and maintain a safe work environment.
For companies looking to improve their safety training, a thorough review of current training materials is a great place to start. Do employees have access to hands-on training with actual components they’ll encounter on the job? If not, partnering with established companies to provide industrial-quality training systems that will stand the test of time will help ensure the continued safety of the workforce.
For example, DAC Worldwide offers a safety training system specifically designed to give employees the hands-on experience they need to master lock-out/tag-out skills. Be sure to check out DAC Worldwide’s Lock-Out/Tag-Out Training System and contact a DAC Worldwide representative to learn how you can improve your training today!
- Published in News
DAC Worldwide Provides Unique Oil & Gas Training Tools
From operators and technicians to mechanics and engineers, oil and gas workers need knowledge and hands-on skills related to a wide variety of common industrial components they’ll encounter in the field. For example, a typical oil and gas worker will interact with a range of pumps and valves on a daily basis.
One such component workers will need to understand is a type of valve known as a back pressure regulator. Back pressure regulators are normally closed valves that precisely control and limit the upstream pressure in a system.
Back pressure regulators maintain a steady upstream pressure of any fluid, gas, liquid, or mixture in a system. They regulate system pressure by adjusting position, widening or narrowing to relieve or increase pressure. Usually installed at the end of a line or process, back pressure regulators ensure that all equipment used before the back pressure regulator receives the correct pressure, maintaining the integrity and effectiveness of the process.
When used in a well head, back pressure regulators control the flow of fluids or gases in the well. The back pressure regulator opens or closes with changes in the pressure of the fluid or gas, preventing overpressure within the well and protecting equipment and personnel from damage or injury. A wellhead back pressure regulator can also be used to maintain a specific pressure in a well for production or injection operations.
To teach oil and gas workers about these common components, DAC Worldwide’s Wellhead Backpressure Regulator Cutaway (295-703) is a sectioned specialty regulator sample that provides convenient classroom and laboratory training in the operation, construction, and maintenance of three industrial back pressure regulator (BPRs), as used in gas and oil service in the oilfield.
These common regulators are often used to maintain steady pressure on an oil column or to assure continuous flow of a producing low pressure well. They’re also regularly found in Xmas tree assemblies in the oilfield.
Through carefully planned sectioning and color-coding, the complete internal configuration of the regulating valve is exposed and showcased. Seal features and hardware locations have been retained, allowing for hands-on training in maintenance. These valves, commonly used in oil & gas production applications and commonly encountered in production wellheads and Xmas trees, are an essential part of comprehensive oil and gas production training.
The Wellhead Backpressure Regulator Cutaway is only one of DAC Worldwide’s many oil and gas training tools. Visit DAC Worldwide online to learn more about other oil and gas training aids, such as the Diaphragm Dump Valve Cutaway, Piston Check Valve Cutaway, Vertical Separator Trainer, and many more!
- Published in News
DAC Worldwide Training Tool Provides Unique Insight into Common Valve
Today’s oil and gas workers need in-depth knowledge of and hands-on experience with a wide variety of different types of industrial valves commonly used in the oil and gas sector. When problems arise at an oil refinery, for example, you want skilled technicians able to troubleshoot and repair systems quickly to avoid a potentially dangerous situation.
One of the most common process controllers you’ll find in oil and gas facilities is the liquid level controller. This key device maintains the level of oil or gas in a container by opening or closing a valve known as a liquid dump valve.
Since the liquid dump valve is located near the level measurement device, it’s possible to use mechanical linkages to coordinate the position of a liquid level float in an oil and gas separator with the position of the liquid dump valve.
In a typical mechanical liquid level controller, the liquid level float that sits atop the liquid is connected to a rod that, in turn, connects to the liquid dump valve. As oil or gas level increases or decreases, the float moves the rod that then opens or closes the liquid dump valve.
For example, if the level of oil in a separator increases, the float will rise, causing the rod to open the liquid dump valve to release oil. Then, as the liquid level decreases and the float lowers, the rod will cause the liquid dump valve to begin to close to decrease the rate of liquid release.
Lever-operated dump valves can be found in a wide variety of oil and gas production containers, including separators, accumulators, treaters, and free water knockouts. To teach oil and gas workers how to maintain, troubleshoot, and repair these common valves, DAC Worldwide’s Lever-Operated Dump Valve Cutaway (295-705) is an actual industrial lever-operated oil dump valve that has been carefully sectioned and color-coded to expose and showcase the complete internal configuration of the valve.
Seal features and hardware locations have been retained, allowing for hands-on training in maintenance. Moreover, common valve makes and models are chosen to ensure industrial relevancy. All cleaning, priming, and painting uses a high-durability urethane coating to ensure this training tool will last for years.
The Lever-Operated Dump Valve Cutaway is only one of DAC Worldwide’s many oil and gas training cutaways. Visit DAC Worldwide online to learn more about other oil and gas training tools, such as the Diaphragm Dump Valve Cutaway, Piston Check Valve Cutaway, Oilfield Backpressure Regulator Cutaway, and many more!
- Published in News
Routine Maintenance Extends Life of Semi-Hermetic Compressors
Do you live in an area that has experienced some of the sweltering heat waves that have plagued the United States the last several years? While scientists and politicians may squabble over the causes of and solutions to the record temperatures we’re seeing, it’s a simple fact that the last few years have been some of the hottest on record.
While increasing global temperatures present a whole host of problems, there’s one industry that’s staying busier than ever when the heat is on. That’s right. We’re talking about the heating, ventilation, air conditioning, and refrigeration industry, more commonly referred to as HVACR.
HVACR professionals, from installers to technicians, keep the machines that make our lives comfortable and enjoyable running smoothly. From the central air conditioning unit that keeps your home cool to the industrial refrigeration units that chill your foods and beverages at the local grocery and convenience store, it’s hard to imagine modern life without the convenience of a wide variety of HVACR equipment.
Unfortunately, the HVACR industry is dealing with the same shortage of highly-skilled workers that manufacturing and dozens of other industries across the country have been facing for years. There simply aren’t enough qualified workers to fill the open positions available in the HVACR industry.
That’s why highly-skilled HVACR technicians are in such great demand these days. Today’s HVACR technicians need expertise with a wide variety of common HVACR components. For example, when dealing with large air conditioning systems or commercial refrigeration units, in-depth knowledge of and experience with compressors is essential.
Some of these systems may feature hermetic compressors, which seal both the motor and compressor inside a leak-proof welded steel shell. Unfortunately, this design makes basic repairs impossible. If the unit fails, it must simply be replaced.
That’s why the design of semi-hermetic compressors has become a popular choice for these systems today. Semi-hermetic compressors also protect the motor and compressor inside a sealed shell. However, unlike hermetic compressors, semi-hermetic compressors can be opened to provide access to many essential mechanical parts, so that they can be maintained and repaired rather than replaced.
Performing routine maintenance on semi-hermetic compressors can extend their service life by many years, saving thousands of dollars. With proper care and maintenance, semi-hermetic compressors can perform at peak efficiency for 8-10 years or more.
If you want to teach an aspiring HVACR technician how to maintain and repair a semi-hermetic compressor, DAC Worldwide’s Semi-Hermetic Compressor Cutaway (373-120) is an expertly-sectioned example of a common intermediate (1”-1 ½”) horsepower semi-hermetic refrigeration compressor that facilitates and supports practical training in compressor design, operating principles, and maintenance.
This unique training tool features a full longitudinal cutaway of a semi-hermetic compressor, which allows for full visibility of the compressor’s operating components, including multiple cylinders, valves, internal motor, and crank shaft. Multiple cutaways unveil all internal components, and cutaway surfaces are enhanced through painting, making the geometry of all components more clear.
The Semi-Hermetic Compressor Cutaway is only one of DAC Worldwide’s many HVACR training cutaways. Visit DAC Worldwide online to learn more about other HVACR training tools, such as the Hermetic Scroll Refrigeration Compressor Cutaway, the Open Drive Refrigeration Compressor Cutaway, the ACR Solenoid Valve Cutaway, and more!
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DAC Worldwide’s Oil Cooler Cutaway Provides Unique Training Opportunity
Many manufacturing processes require the transfer of heat from one fluid (liquid or gas) to another, and most of those processes use heat exchangers to accomplish this task. In a heat exchanger, the two fluids do not make direct contact. Instead, heat passes from the hotter fluid to the metal isolating the fluids and then to the cooler fluid.
You’ll find heat exchangers in a wide variety of industrial applications, including heating, ventilation, and air conditioning (HVAC) systems; preheaters or coolers in fluid systems; radiators on internal combustion engines; and boilers, evaporators, and condensers used with fluids like oils, wastewater, hydrocarbons, biogases, etc. in industries such as oil and gas refining and power generation.
Heat exchangers come in a wide variety of shapes, sizes, and designs. For example, a finned tube oil cooler is a specific type of heat exchanger used to cool fluids, such as oil. A finned tube oil cooler features a bundle of tubes with fins that increase the surface area usable for heat transfer.
The tubes in a finned tube oil cooler can be made of a variety of materials, including aluminum, copper, or stainless steel. The fins are often made of the same material, although they can be made from another material, like carbon steel.
A finned tube oil cooler cools oil by circulating the oil through the tubes while water or another cooling fluid flows over the fins. The oil’s heat transfers from the fluid to the fins first and then to the cooling fluid, which transports the heat out of the system.
DAC Worldwide’s Oil Cooler Cutaway, Finned Tube Bundle-Type (273-610F) is a desktop training tool for industrial heat exchanger training that supports operations and skills training relating to this common device found in process systems of all types.
Finned tube heat exchangers have a wide variety of applications in the oil & gas, petrochemical, and power industries. These heat exchangers offer reliable operation, low operating costs, and high performance.
Oil coolers have some specific advantages. Oil has a higher boiling point than water, so it can be used to cool items 100°C or higher. In addition, oil is an electrical insulator, so it can be used inside of or in direct contact with electrical components.
Multiple cutaways unveil primary details and features, including tube layout, tube sheets, aluminum fins, nozzles, flow path, and gaskets. The cutaway consists of an actual industrial, 2-pass, heat exchanger/cooler. Common makes and models are chosen for industrial training relevance.
Mounted on a powder-coated, formed-steel mounting stand and allowing mounting on standard DAC Worldwide display and storage products, the device will provide years of use in any industrial training program.
DAC Worldwide’s Oil Cooler Cutaway, Finned Tube Bundle-Type is a professionally crafted, heavy-duty, durably coated, and fully detailed teaching aid that will provide years of service in the training lab or classroom. Be sure to check out DAC Worldwide’s website to explore a wide variety of other hands-on cutaways that feature the real-world components workers will encounter in the field!
- Published in News
Focused Training Key For Industry
Is the pandemic over? Some days it’s difficult to tell, as the ripple effects of continued cases of COVID-19 continue to pop up and create problems for both workers and manufacturers. Although the severity of pandemic-related disruptions has certainly subsided, industries around the world are still struggling with the aftershocks of a tumultuous few years.
In addition to ongoing supply chain woes, manufacturers are also contending with a labor marketplace that has changed fundamentally as a result of the pandemic. Prior to the pandemic, industry was struggling to fill open positions with qualified workers. Today, these struggles remain and in many areas have gotten even worse.
As a result, industries are placing a great emphasis on skills assessment to ensure that new hires can hit the ground running. In addition, upskilling current employees has taken on new significance, as industries seek to make the most of available human resources when it’s difficult to hire qualified new workers.
In this article, we’ll take a look at the current skills gap, the type of skills assessment and training that industry needs, and how the training tools offered by DAC Worldwide can help employers and instructors assess and train workers for the jobs of today and tomorrow.
How Wide is the Skills Gap?
Now that the worst of the pandemic appears to be behind us, things should be slowly getting better, right? Why then do manufacturers seem to be falling farther behind? According to an article by Alexandra Johnson:
“Before COVID, the situation was bad, but post-pandemic it has become even worse. Despite lockdown lifting, the industry is reporting over 515,000 jobs need filling, just to meet demand.”
Commonly known as the “skills gap,” there remains a sizeable disparity between the supply of highly-skilled workers and the demand for these workers in today’s industrial labor market. In fact, experts predict the skills gap is going to get even worse in the foreseeable future.
A study conducted by Deloitte for the Manufacturing Institute estimates that, over the next decade, almost 4.6 million manufacturing jobs will need to be filled. However, because of the skills gap, as many as 2.4 million — more than half! — of those jobs could go unfilled.
In a recent Forbes article, author Graham Glass notes that “[n]early half (46%) of learning and development (L&D) leaders say the skills gap is widening in their organization, and 49% say executives are concerned employees don’t have the right skills to execute business strategy, per findings from LinkedIn Learning’s ‘2022 Workplace Learning Report.’”
What is industry to do? Glass advises that “organizations need to emphasize employee upskilling, reskilling and right-skilling — and anticipate the skills employees need to succeed in their positions…By assessing the business’s needs pre-training (to develop training content) and post-training, companies can work to bridge skills gaps and create training programs that are impactful and useful to employees and the organization alike.”
Skills-Based Hiring
What’s the best approach for industry to take to bridge the skills gap? Should industry simply hire anyone they can get their hands on and then train them to do the jobs they need done? For many reasons, that strategy is probably not the best solution.
Industry is already struggling with a host of issues left over from the pandemic. Most companies don’t have the bandwidth to babysit new workers while they acquire the training they need. Many also don’t have either the personnel or the tools to effectively train new workers.
That’s why, in an article in the Harvard Business Review, LinkedIn CEO Ryan Roslansky advocates for a new skills-based approach to hiring. Roslansky urges employers to “[f]ocus on the results you’d like to see, rather than the type of qualifications that you think could deliver them. Highlighting the desired skills — the candidate’s ability to perform certain tasks — gets to the same results without creating an unnecessary barrier to entry, like a requirement for a four-year degree.”
In an article by Adina Miron, the author agrees:
“Skills-based hiring enables employers to hire for the skills gaps that exist within their organization. Rather than focusing on experience, education, or certifications, companies should focus on identifying candidates with the needed skills to fill open positions.”
Roslansky echoes these thoughts:
“Shifting to a skills-focused approach is a viable solution to an evolving workforce dilemma…Stay focused on skills — and the assessments that can measure them…there are plenty of ways to gauge a candidate’s ability to perform without relying on their education or experience as proxies.”
How do employers shift to a skills-based hiring approach? Unfortunately, generalized assessments and comprehensive training systems can be difficult to use in the context of hiring new workers in industry. Why? The answer can be found in the concept of specialization of labor.
According to an article by Sampson Quain:
“Specialization of labor…refers to a process in business in which large tasks are divided into smaller tasks, and different employees or different groups of employees complete those tasks. Specialization is highly desirable in large-scale operations such as…manufacturing because it allows workers with specific skill sets to efficiently perform a specific task.”
For example, a manufacturer may need to hire someone with a specific skillset related to the operation, maintenance, troubleshooting, and repair of mechanical belt drives. A prospective candidate might claim to have general mechanical knowledge and skills, but how can the employer know whether the worker has the specific belt drive skills it needs?
To effectively use a skills-based hiring approach in manufacturing, employers need focused assessment and training tools that can be used to adequately determine a potential worker’s skills in a very specific area.
Training at the Speed of Industry
Industry must also dedicate resources to ongoing training for current workers. The need for ongoing training is real and cannot be ignored. Industries today need to attack the skills gap with a combination of skills-based hiring and instituting training of current workers that is practical and effective.
In his Forbes article, Glass argues that “a personalized approach to training can also be useful to employees and companies.” However, he acknowledges that, “[i]n large companies, especially, creating individualized learning paths manually can be time- and resource-intensive.” He also points out that “employees need training that fits into their workflows.”
Most companies cannot afford the luxury of sending workers off-site for a week or more at a time for in-depth training. Instead, they need focused, skills-based training that allows workers to obtain the hands-on skills they need while minimizing the effect on production of time away from the workplace.
Fortunately, a variety of training tools exist that can offer industries time-saving, cost-effective solutions for focused skills assessment and hands-on training. In the next section, we’ll take a closer look at DAC Worldwide’s range of single-topic trainers that can help industry move to a skills-based hiring model and also upskill current employees.
DAC Worldwide Offers Focused Assessment & Training Tools
DAC Worldwide offers training systems for a variety of industry sectors, including advanced manufacturing, process/chemical manufacturing, marine, military, oil and gas, and power generation. These training systems also cover many different technical topics, such as electrical and electronics; heat transfer and steam; mechanical drives; oil production; process control and instrumentation; and pumps, compressors, and valves.
Rather than broad-based training in multiple areas, DAC Worldwide’s training systems provide hands-on training focused on specific tasks. This makes them particularly helpful to employers for skill assessment (either pre-employment or for upskilling purposes). For example, DAC Worldwide offers training systems targeted specifically at key mechanical maintenance skills:
Belt Drive Training System
The Belt Drive Training System (201-000) allows for convenient assessment and training in the identification, installation, tensioning, and alignment of common belt drives types found in industry. Featuring hardware for applications related to multiple matched belts, fractional horsepower belts, positive drive belts, and variable pitch sheaves, the system provides a variety of training and assessment applications in one benchtop piece of equipment.
Coupling/Shaft Alignment Trainer
The Coupling/Shaft Alignment Trainer (208-000) allows for realistic training and assessment in shaft alignment. Designed based on the dimensions of a common ANSI centrifugal pump, this trainer can assess and train workers on all common alignment techniques and tools. Training and assessment topics include using a dial indicator in coupling/shaft alignment, the reverse dial indicator method, fabrication of shaft keys, and installing a flexible disc coupling.
Chain Drive Training System
The Chain Drive Training System (223-000) allows for in-depth assessment and training in industrial chain drives, heavy/silent chains, and sprocket set usage. Using industry-standard components workers will encounter on the job, this training system provides a complete training and assessment experience covering topics such as taper lock bushings, chain drive maintenance, installation/alignment of chains, and tensioning of chains.
Let DAC Worldwide Help You Fill Your Skills Gaps
The mechanical assessment and training tools highlighted above are just a few examples of the variety of technical training tools DAC Worldwide manufactures. In addition to training systems, DAC Worldwide also offers a wide range of industrial cutaways, detailed scale models, and sample boards featuring industrial components.
Contact a consultant with DAC Worldwide today to learn more about how their technical training tools can help you build the assessment and training program your company needs. Using DAC Worldwide training and assessment tools, you can transition to a skills-based hiring approach and fill the skills gaps in your organization!
About Duane Bolin
Duane Bolin is a former curriculum developer and education specialist. He is currently a Marketing Content Developer in the technical training solutions market.
- Published in News