Immersive learning through virtual reality (VR) simulation is one way organizations can help prepare workers to operate forklifts. VR training can enhance forklift operator training programs with benefits for both trainees and organizations.
The Case for Virtual Reality
Much of the material handling equipment used in supply chains is highly specialized. Improper operation can result in increased risk to employees, disruptions in workflow, and damaged products and equipment.
This is why a robust and effective operator training program is essential. For instance, a forklift’s multifunction control handle may look like a video game joystick, but it requires substantial operator skill and training to master. Operators must understand how the control works and demonstrate proficiency in its use.
This is where virtual reality can play a substantial role. Operators are more likely to retain what they have learned when actively involved in simulated tasks that engage sight, sound and touch, rather than by just observing.
A VR forklift simulator can help operator trainees gain familiarity with the forklift’s operation in a controlled, virtual environment. Traditionally, an operator is provided training videos and manuals in a classroom setting. Then the trainer teaches the operator about the forklift with the unit powered down and its battery removed. At this stage the operator-in-training must demonstrate initial familiarity with the controls, without the feedback provided by operating a live lift truck. The trainee does not practice moving and maneuvering the truck until the truck is “live” and the stakes for errors rise significantly. A training regimen that includes VR can provide trainees an opportunity to build confidence as they begin to acquire proficiency in a controlled, virtual world where mistakes are simply learning opportunities.
VR training systems can also instantly track and assess operator performance and give feedback and guidance based on the operator’s actions. Trainees can begin to develop their skills on the spot, and trainers can keep track of individual progress. Tracking performance data helps identify areas where the operator may need more practice and ensures they are prepared for live operations.
Tips for Integrating VR into Forklift Training
VR is an additional tool that is available for training forklift operators. It’s not a miracle fix or a one-size-fits-all solution, but it can be an effective element in addition to required training. We developed an 11-step Demonstrated Performance (DP) training program to help companies train new forklift operators. This DP operator training program can be supplemented with VR simulation equipment to bridge a gap between observation and actual operation.
The following tips can help companies realize tangible benefits from adding VR to their forklift operator training programs.
1. Determine how the technology best fits into your operator training program.
By staggering the conventional parts of early-stage operator training with controlled, VR-based sessions, trainees can demonstrate what they’ve learned in theoretical lessons. They can learn how to anticipate and quickly identify unexpected circumstances, then react appropriately to the situation without real-life consequences.
Integrating VR training into the early steps of a training program helps reinforce lessons like safe raising and lowering of forks and pallet acquisition. Trainees also virtually perform the most important actions they’ll perform later on a live forklift: steering, travel, braking and plugging.
2. Understand and account for the limitations of technology.
Technology cannot completely replace traditional, hands-on training. VR training, while not an OSHA requirement, is a supplement to a conventional training program. Safe behaviors start with trainers and managers that help trainees understand forklift operation and develop safe operating habits. VR should not be considered a replacement for these essential leadership roles and training requirements.
Another possible limitation is the equipment itself. Ideally, a VR training system should include physical equipment that replicates the operator compartment, including controls used by the operator’s hands and feet. This provides the operator with an accurate feel of the controls they will encounter on the actual forklift.
Some VR training systems can provide haptic feedback, which gives physical feedback to the trainee like emitting a vibration when a trainee bumps a virtual shelving unit with their simulated forks. This vibration or “buzzing” provides physical feedback to the trainee, in addition to the VR system’s visual and audible feedback.
Physical limitations of the operator trainee can be another limitation. Many VR training integrators have observed that sessions lasting more than five minutes can increase the trainee's risk of experiencing motion sickness. Sessions are most effective when kept short. Trainees can experience multiple simulation sessions in the course of their training while minimizing the risk to their physical wellness.
3. Carefully select your VR training partner.
It is essential to choose a VR training program that provides realism but is also flexible. While an immersive VR environment is helpful for the training experience, it shouldn’t be treated like a video game. The system should focus on faithfully representing actual forklift controls and an actual forklift’s response to operator commands.
Ideally, VR training software will provide flexible scenarios that help address the specific needs of your application, such as a crowded work environment or a low-lit, narrow aisle storage configuration, as well as hardware that matches the material handling equipment used in your warehouse. For example, we collaborated with VR industry experts to develop a VR training system, which includes a floorboard equipped with a brake pedal and presence switch, and an actual multifunction control handle that is used on our reach trucks and stand-up counterbalance forklifts.
The combination of a VR headset, a laptop computer, hand controls, floorboard and specialized software can provide trainees a controlled way to develop their skills without the added time and cost of scheduling and setting up scenarios using full-scale forklifts in allocated physical spaces associated with traditional training.
As you explore adopting VR forklift operator training at your organization, remember that no VR training can replace conventional forklift operator training. However, the integration of virtual training to classroom, demonstration and hands-on learning should be given strong consideration in providing new forklift operators with the skills they will need to move products safely and efficiently.
