Kobus Vermeulen | Executive | Direct Sales | Process Automation | Schneider Electric | mail me |
Industrial operations are, like the rest of the world, facing a fundamental generational workforce change. Today, most baby boomers, those experienced operators aged between 61 and 79, are projected to retire by 2035.
As a younger, more mobile generation steps in, the traditional model of long apprenticeships and gradual knowledge transfer is no longer sustainable. The result is a steep learning curve that demands innovative solutions.
Considering this challenge, operator training simulators have become a highly viable option. They help organisations onboard talent, preserve institutional knowledge and maintain safety in potentially hazardous environments.
A workforce in flux
Younger employees are entering industrial workplaces with strong digital fluency but limited interest in long apprenticeships.
According to Forbes, Gen Z values autonomy, flexibility and purpose-driven work. They prefer mentorship programmes that are interactive, personalised and digitally accessible rather than long-term shadowing. Therefore, it is critical to compress years of on-the-job experience into accelerated training programmes.
Operator training simulators address this challenge directly by providing immersive and realistic experiences. These platforms replicate live plant systems. They give new operators hands-on experience that builds confidence and competence before they handle real assets.
Accelerating training
To further enhance training, organisations should consider system-agnostic operator training simulators. These flexible solutions work across diverse control systems and multiple sites. This adaptability benefits companies with evolving automation platforms.
Instead of investing in separate tools for each system, companies can use one scalable platform. It adapts to varied environments and streamlines training efforts. This universality shortens onboarding times and simplifies integration. Trainees gain realistic experience without needing prior familiarity with specific control systems. This accelerates the process of achieving full competency.
Furthermore, centralised training can be standardised across facilities. This ensures best practices are shared consistently, regardless of geography or technology.
Safeguarding expertise
One of the most pressing concerns in modern industry is the loss of institutional knowledge as senior operators retire. As Nobel laureate Werner Heisenberg noted, “An expert is someone who knows some of the worst mistakes that can be made in his subject, and how to avoid them.”
Experienced operators know how to respond to rare disturbances and recognise subtle process deviations. They make intuitive decisions in emergencies. Operator training simulators capture this expertise and embed it into training modules. This ensures it remains accessible to future generations.
By involving retiring operators in scenario development, organisations can preserve both procedures and practical insights. These scenarios form a living library of experience that new recruits can revisit. In doing so, they bridge the generational gap and protect against the erosion of operational memory.
Establishing a safety-first culture
Beyond technical skills, operator training simulators cultivate a strong safety mindset. By simulating both routine operations and emergency events, trainees internalise safety protocols in a controlled environment.
The ability to make mistakes without endangering equipment or personnel reinforces the importance of vigilance. Repeated exposure helps make safety a habit.
Additionally, team-based simulations strengthen communication, coordination and accountability. These are all essential elements of a resilient safety culture. Whether an operator has one month or twenty years of experience, operator training simulators ensure all staff follow the same safety standards.
Operator training simulators offer modular, updatable training scenarios. These evolve alongside plant processes, regulatory shifts and industry innovations.
