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development of a training manual for university of wisconsin

1. Although computer based simulators have only been around since the 1950s when the first computers appeared the basic idea of simulation as a teaching technique has been practiced for a long time especially in the form of models games or role playing Marquardt and Kearsley 1999 Simulator use has increased many folds with the use of computer based systems as the computer can be programmed to model almost any process or function In the world of printing where printing presses can cost in excess of ten million dollars computer based simulators are cost effective training tools Simulators can increase productivity by training employees in a life like setting without taking expensive equipment out of production Today s computer based printing press simulators are oriented towards the press operator training him or her in operation skills and troubleshooting techniques The purpose of this study is to develop and pilot test a training manual for the PackSim gravure printing press simulator for use in the University of Wisconsin Stout s Graphic Communications Management GCM program The GCM program is starting to developed curriculum to utilize a number of simulators in printing press processes This training manual will allow the GCM program to incorporate the PackSim gravure printing press simulator into its curriculum as a self directed training module Pilot testing of the training manual will be the method of evaluat
2. GCMBUNSTOUT APPENDIX D SINAPSE GRAVURE ASSOCIATION OF AMERICA 91 Contact North American Contact 92 Sinapse Graphic International Bat Epicure Les Algorithemes Route de L Orme aux Merisier 91194 Saint Aubin Cexex France http www sinapsegraphic com Gravure Association of America Inc 1200 A Scottsville Road Rochester NY 14624 http www gaa org
3. Simulators have been around for many years Early simulators where unsophisticated yet performed the training function they were intended for It s also a domain closely associated with military training simulators of weapons systems e g wooden guns and horses have been 12 used for many centuries Marquardt and Kearsley 1999 Aircraft simulators started out with the first proposals for truly ground based trainers which were in effect aircraft tethered to the ground but capable of responding to aerodynamic forces One such device was the Sanders Teacher Moore 2002 As technology advanced so did simulators The level of complexity has escalated to the point where some simulators need as much training to operate than the equipment or process they simulate An example is the modern aircraft simulator where the level of complexity rivals that of an operational aircraft One of the enduring and important questions of the simulator field remains How realistic does the simulator need to be in order to produce effective training Marquardt and Kearsley 1999 This study will attempt to answer this question with a pilot testing of the training manual and a follow up survey of the participants Computer Based Simulation Computer based simulators have been around since the1950s and they have grown in complexity along with computer advancements A computer simulation offers companies the chance to preserve thi
4. 12 Did the format of the manual help you or confuse you Explain 13 How could this manual be improved to make it better 14 Did the training manual help you understand the PacSim simulator operation APPENDIX C PACKSIM TRAINING MANUAL 53 PACKSIM SIMULATOR TRAINING MANUAL By Jerry Addie University of Wisconsin Stout Graphic Communications Management aa NAAMSE Sinaspe PacSim Simulator UW STO UT Reproduced with penuission Graphic Communications Management Table of Contents Introduction Overview Chapter 1 Simulator Familiarization Main Control Screen Icons Press Room Icons Press Room Component Identification Web Viewer Chapter 2 Get the Press Up and Running Main Control Panel Controls Help Screen Drive Panel Options Web Viewer Component Identification Chapter 3 Exercises and Problem Resolution Exercise Procedure Problem Resolution Overview Print Fault Descriptions Exercises 56 Fig 1 PackSim gravure press room Introduction The PackSim Gravure Printing Press Simulator by Sinapse Graphic is a computer based program designed to build experience and confidence in the gravure press operator It was developed such that the novice computer user with little or no training on the press can learn to operate and troubleshoot everyday press problems The exercises have a variety of difficulty levels and range from single situations to multiple comple
5. 22 allows you to toggle between Figures 2 23 or 2 24 and the Full Screen View Figure 2 23 Print Copy Vs Color OK con Side by Side View 78 Cae amp to Bottom View Figure 2 24 Print Copy Vs Color O 18 Clicking the Printed Copy Vs Color OK Figures 2 23 or 2 24 allows you to choose either side by side views or top to bottom views By selecting one of these views it allows you to compare the current view with the required view showing any faults that may be in the printed job The Color OK view is on the right in the Side by Side and on the bottom in the Top to Bottom view Figure 2 25 Densitometer icon 19 Clicking the Densitometer Figure 2 25 allows you to bring up the Densitometer in a separate window See Figure 2 26 below Gear Side 1 25 Density Operator Side 1 25 Reference Density 1 25 Figure 2 26 Densitometer Window 20 Clicking on a separate color in the Densitometer Window Figure 2 26 will show you the density of that color on the gear side and operator side along with the reference good density Gear Head Tail Operator 79 Figure 2 27 View Movement Towards icons 21 Clicking on one of the View Movement icons Figure 2 27 allows you to view the different areas of the Web Viewer N wu uw ws L get densitometer Figure 2 28 Bottom Left of the Web Viewer 22 In Figure 2 28 the mouse cursor has been
6. How to Research Write Test Edit and Produce a Software Manual pp 27 54 Concord CA UnTechnical Press Brendel K amp DeCaria D amp Kochnowicz 1999 A Look Back at the GCM Program In Graphic Communications Management Newsletter 23 pp 2 3 Budgett Henry 1989 Desktop Publishing Company Ltd Typesetting and Publishing Glossary Retrieved April 5 2003 at http www sos com au files glosray html Business and Industry Partners n d College of Technology Engineering and Management University of Wisconsin Stout Retrieved April 5 2003 at http www uwstout edu ctem busin html Clark C 1999 CBT Versus Classroom Training Some Differences In Developing Technical Training A Structured Approach for Developing Classroom and Computer Based Instructional Materials 203 216 2 Edition Washington D C International Society for Performance Improvement Definition of Graphic Communications and Explanatory Paragraphs n d Retrieved April 5 2003 at http www profectus com definition htm Gravure n d Retrieved February 16 2003 from Western Michigan University Department of Paper Engineering Chemical Engineering and Imaging Web site http www wmich edu ppse gravure pp2 htm Harrison N 1999 Screen Design for CBT and multimedia In How to Design Self Directed and Distance Learning A Guide for Creators of Web Based 45 Training Computer Based Training and Self S
7. IDLE JOG STOP EMERGENCY RUN STOP SET SPEED IMPRESSIONS ROLLERS UP DOWN PRESS DRYERS ON OFF FAST RAMP ACCELERATION Figure 2 5 Drive Panel Options Main Control Panel 71 8 Figure 2 5 identifies the controls for the press drive Here press Speed is set as well as the on off buttons for Power Web Viewer Web Break Detectors Impression Rollers and Dryers Note To stop the press use the Stop button The Emergency Stop button should only be used in Emergencies as the forces generated to stop the press can cause possible press damage 9 With the Main Control Panel open Start the press by completing the following steps in sequence See Figure 2 5 for full view of the Main Control Panel Step 1 Click on the Run button on the Speed Panel of the Main Control Panel Figure 2 6 Step 2 Click on the Impression Rollers Up Down on the Main Control Panel to light the button and place the impressions rollers in the down position Figure 2 7 Figure 2 7 Impression Rollers Dryers Switch 72 Step3 Turn on the Dryers by clicking on the I O Dryers switch Figure 2 7 Step 4 Click on the Thumbs Down button to check print copy quality If printing is good Thumbs Up will be displayed In the event the copy is not good the following warning will be displayed PACKSIM PAY ATTENTION Your print copy is bad You have to correct the print Faults before saving Step 5 Press speed
8. as a controlling part of the simulator In the use of a simulator the user s experience has much bearing on what the method or methods of training will be However great care should be taken in selecting the appropriate training delivery method Often the choice is not what one method should be used Instead it may be more appropriate to think of what combination of methods may be most cost and time effective and also is most likely to encourage learning and application Rothwell and Benkowski 2002 Finding the right method to utilize with the PackSim gravure printing press simulator is a large consideration This computer based simulator allows the student to practice the gravure press processes Yet when problems arise troubleshooting leaves the student to their own experience to solve or seek out the help of a trainer Simulation methodology is closely associated with the systems 16 approach since it involves building models identifying cause and effect input output relationships among variables defining elements subsystems and boundaries and examining feedback sequences Marquardt and Kearsley 1999 Yet as good as any simulation can be the human element must be taken in to account Schank 1997 states People naturally teach themselves When something goes wrong people automatically ask themselves how they have messed up and seek advice in order not to repeat the same mistake This is where the
9. be useful in the operation of the simulator An overwhelming number 75 of the respondents found the training manual chapter layout and notes to be useful when using the manual These results even though the number of total respondents are low provided enough information to address changes and concerns to improve the helpfulness in final version of PackSim training manual Conclusions The researcher came to the following conclusions based on the findings of the study 42 1 A self directed manual was an effective method to use with the PackSim gravure printing press simulator 2 Pilot testing of the PackSim training manual and completion of the survey questionnaire brought validity to the study 3 The PackSim training manual is a useful tool to train students in the use of the PackSim gravure printing press simulator 4 The training manual will be incorporated into the GCM program s curriculum for use of the PackSim simulator 5 Revision of the PackSim training manual will incorporate changes suggestions from recurring comments on the surveys particularly those comments on how to use and proceed through the manual 6 Further use and feedback will be part of a continued improvement process of the manual Recommendations The printing and publishing industries rely on universities like UW Stout to develop their curriculum to cover the various aspects of the industry Gravure is one of several methods in which to print
10. either Good or Not Good in the history box If Not Good comes up you can click on the text Restore Web Path then click the Action button to resolve the problem The Restore Web Path option is only available if the press is SIOPPED Figure 1 10 Rewind View icon Figure 1 11 Unwind View icon 3 Clicking on the Rewind Unwind view icon Figure 1 10 1 11 toggles between the rewind end or unwind end view of the press Figure 1 12 Web Viewer icon 4 When running the simulator in the one screen option the Web Viewer icon Figure 1 12 becomes available Clicking on this takes you to the Web Viewer In the two screen option this icon is not displayed Figure 1 13 Rewind View Exit icon 5 Clicking on the Rewind View Exit icon Figure 1 13 allows you to exit the simulator 62 Environment Rewind Printing Unit5 Conditioner Web Guide Festoon Main Control Panel Unwind Figure 1 14 Press Room component identification 6 Figure 1 14 shows the various press components within the Press Room These components can be readily identified by scrolling the mouse across them and a label tag will appear showing the name of the device 63 CHOOSE WEB VIEWER POSITION PRINT COPY FULL SIZE VIEW QUARTER SIZE VIEW SIXTEENTH SIZE VIEW MAGNIFIER CONTRO STRIPS VIEW GO FROM SPLIT Jj CREEN TO re FULL SCREEN fj SHOW PRIN C
11. for a training manual 3 Selection of human subjects 4 How to pilot test the training manual 5 How to evaluate the pilot and accompanying survey Description of Research The research methodology used in this study is qualitative Although there are elements of quantitative research in this study the overall underlying methodology is qualitative The study is to develop a usable training manual for an existing computer based simulator and obtain feedback from the pilot test The GCM program has developed in depth courses to increase a student s skills and abilities in the realm of offset sheet fed web and flexography press processes UW Stout s GCM program strives to provide all its students with up to date technological advancements in the printing industry Gravure presses are a cost prohibitive equipment addition to the university The advent Sinapse s 23 PackSim gravure printing press simulator allows the students to learn on a simulator of the gravure press at an affordable cost The PacSim gravure printing press simulator operates on the premise that anyone with basic computing skills and background knowledge in gravure printing presses can follow and operate the simulator successfully with training The PackSim simulator will simulate a multitude of real world problems on a gravure printing press The researcher will develop with the aid of GCM students a training manual that will guide the subjects throu
12. likert scale and subjective question types A total of 20 surveys were given out to students in class and 8 surveys returned for a response rate of 40 percent Findings and Analysis The majority of the questions of the survey deal with the organization and usefulness of the PackSim gravure printing press training manual The questions were designed to determine if the respondent could make heads or tails out of the training manual Then apply the information the respondent learned using the PackSim training manual to accomplish the exercises using the PackSim 31 simulator The respondents then could provide feedback on the manual by responding to the survey provided Table 1 Question 1 Gravure process exposure What is your exposure to the Gravure printing of process Respondents None 0 0 Read about it 3 37 5 Had lecture demonstration 4 50 Had several lectures and or demonstration 5 62 5 Field Trip 3 37 5 Work experience 1 12 5 Gravure day sessions 6 75 Other 0 0 The table above indicates that all participants had some form of exposure to gravure printing process Several respondents checked both having had one lecture and several lectures so the percentages for those two areas equal over a hundred percent Numerous respondents replied that more than one type of exposure had been experienced Table 2 Question 2 PackSim usage 32 Prior to th
13. major printing processes has left the GCM program with the dilemma of how to afford the equipment and find the physical space needed for such equipment The GCM program has single two and four color sheet fed offset presses along with a narrow web flexography press for the students to use Yet even with this great variety of equipment there are holes in the program No gravure no web offset no wide web flexography and no corrugated flexography A French firm Sinapse has developed a number of computer based printing press simulators for sheet fed offset web offset gravure and flexography with variations of each type Stout has Sinapse s heat set web offset gravure and flexography simulators These simulators could eventually close the technological gap at UW Stout at an affordable price This study will focus on the simulator for packaging gravure PackSim Simulation History Simulators devices intended to model actual equipment represent one of the oldest domains of technology based training Marquardt and Kearsley 1999 Many persons when asked can name a few common uses of simulators such as aircraft flight simulators or driver training simulators It s also a domain closely associated with military training simulators of weapons systems e g wooden guns and horses have been used for many centuries Marquardt and Kearsley 1999 Simulators continue to play even greater roles in the military today In the
14. number of three letter descriptions to list print faults and are defined as follows BLD Bleeding BLK Blocking BTF Bent Flaps BUB Air Burst in Cylinder CFP Uncuts Flaps CHT Chattering CLO Color Off CMK Cylinder Mark CRL Cross Lines CRS Chrome Streak CTG Bad Paper Coating CTJ Cutter Jam CTR Cutting Register CUR Curling DGG Dragging DIB Dent in Box DIS Dimensional Stability in Substrate DRD Dropped Dots DRG Drags DSJ Delivery Section Jam GRC Greasing HAZ Hazing HOL Holes IFF Ink Flow IRD Defect on Impression Roller ISP Ink Spots MPR Missing Prints MTL Mottling NEM No or Poor Embossing NIK Broken Nicks OFS Set Off PHO Stripper Pin Hole PIK Picking REG Misregister SCR Screening SKN Smashed Knives SKR Uneven scores SCT Stitching problem SVR Solvent Retention TBJ Tab Breaker Jam TDB Delivery Table Trim TCS Telescoping Roll VOL Volcano WRN Wrinkles Note These three letter codes appear with the exercise giving you a hint as to what the problem is on press and this should start you in the right direction to solve the problem 6 During troubleshooting don t let the complexity of the simulator interfere with your problem resolution Think about the exercise and the information already provided Don t be afraid to explore the different views and parts of the Main Control Panel Press Room and Web Viewer 86 7 The exercises selected are given to stimulate your thoughts about the Gravure printi
15. past fifty or so years their wide spread use in industry has exploded This increased use and reliance on simulators has been due in part due to the computer Although computer based simulators have only been around since the 1950s when the first computers appeared the basic idea of simulation as a teaching technique has been practiced for a long time especially in the form of models games or role playing Marquardt and Kearsley 1999 Simulator use has increased many fold with the use of computer based systems as the computer can be programmed to model almost any process or function In the world of printing where printing presses can cost in excess of ten million dollars computer based simulators are cost effective training tools Simulators can increase productivity by training employees in a life like setting without taking expensive equipment out of production Today s computer based printing press simulators are oriented towards the press operator training him or her in operation skills and troubleshooting techniques Gravure History The origins of gravure printing were with the creative artists of the Italian Renaissance in the 1300s Gravure 2003 Today gravure is used for printing packaging magazines newspaper inserts and even wallpaper are printed from this process Gravure printing is an expensive process mainly used for long runs in the millions of impressions where errors or problems can lead to expe
16. that create develop produce and disseminate products utilizing or incorporating words or pictorial images to convey information ideas and feelings Graphic Communication products facilitate learning enjoyment motivation and commerce Graphic Communications includes the family of market segments embracing the technologies of printing publishing packaging electronic imaging and their allied industries they are often referred to as the graphic arts print or imaging industries Definition of Graphic 2003 Gravure Process for the manufacture of gravure printing masters cylinders where e g an electromechanically controlled stylus cuts recesses cells into the copper layer of the gravure cylinder The size and depth of the cells are varied in accordance with the image The engraved cells are filled with ink in the printing process and the ink is then transferred onto the substrate Kipphan 2001 See Figure 1 1 Gravure printing process and Figure 1 1 a revised version with industry standard titles Intaglio A printing process in which words pictures or designs are engraved into the printing plate or cylinder Prust 2003 Offset lithography A printing method whereby the image is transferred from a plate onto a rubber covered cylinder from which the printing takes place Budgett 1989 Simulator any device or system that simulates specific conditions or the characteristics of a real process for the pu
17. with the researcher Please read the instructions carefully This data is an important part of this study to help in the process of developing a working training manual If you have any questions please contact Jerry Addie the primary researcher at 715 232 1254 1 What is your exposure to the Gravure printing process Please check as many that apply as to your involvement None Field Trip Read about it Work experience Had one lecture demonstration Gravure day sessions several lectures and or Other demonstration 2 Prior to the study have you used the PackSim simulator Yes No The following statements will be on the use of the training manual Please respond to the statements using the following rating scale Please circle your selection Strongly Agree Agree No Opinion Disagree Strongly Disagree 1 2 3 4 3 I reviewed the training manual prior to starting the testing 123 4 5 4 I find the manual useful 123 4 5 5 I found the Chapter layout useful to find helpful information during simulator usage 123 4 5 6 The notes provided useful tips 12345 7 The figures helped in using the simulator Bh MES 8 The instructions were clear 12345 9 The manual helped in doing the exercises 123 4 5 52 10 Check any parts of the manual that did not work with the simulator Explain L Introduction L Starting the press L Exercises 11 List any instructions that were unclear or missing
18. Appendix B Appendix C Appendix D Survey Instrument Findings and Analysis Summary Conclusions and Recommendation Summary Restatement of the Problem Methods and Procedures Major Findings Conclusions Recommendations CONSENT FORM SURVEY INSTRUMENT PACKSIM TRAINING MANUAL SINAPSE GAA INFORMATION 30 30 39 39 40 41 41 42 44 47 50 53 91 Table LIST OF TABLES Question 1 Question 2 Question 3 Question 4 Question 5 Question 6 Question 7 Question 8 Question 9 Page 31 32 32 33 33 34 35 35 36 1 LIST OF FIGURES Figure Page 1 1 Gravure printing process 10 1 1 Revised version of Gravure printing process 10 xi Acknowledgements There are many people that I need to thank The first is my family for their support love and encouragement that makes this study possible Special thanks go to my wife Sally who continues to give me inspiration and the drive to complete this degree I would like to thank my research advisor James Tenorio for his patience with the many writes and rewrites he endured through out this process Also thanks for his ability to put all my problems in context to make the process go a lot easier There are a number of other people at UW Stout that I owe my gratitude towards Thanks go to Steve Schlough and Kat Lui for sound advice and encouragement they have given me during this research process Chapter I Int
19. DEVELOPMENT OF A TRAINING MANUAL FOR UNIVERSITY OF WISCONSIN STOUT S GRAPHIC COMMUNICATIONS PROGRAM S GRAVURE PRINTING PRESS SIMULATOR by Jerrold O Addie A Research Paper Submitted in Partial Fulfillment of the Requirements for the Master of Science Degree in Training and Development Approved for Completion of 4 Semester Credits TRHRD 735 Field Problem in training and Development by Dr James Tenorio Research Advisor The Graduate College University of Wisconsin Stout May 2003 The Graduate School University of Wisconsin Stout Menomonie WI 54751 ABSTRACT Addie Jerrold O Writer Last Name First Initial Development Of A Training Manual For University Of Wisconsin Stout s Title Graphic Communications Program s Gravure Printing Press Simulator Training and Development Dr James Tenorio May 2003 102 Graduate Major Research Advisor Month Year No of Pages Publication Manual of the American Psychological Association Fifth Edition Name of Style Manual Used in this Study Simulators have been around for many years in various forms Simulators devices intended to model actual equipment represent one of the oldest domains of technology based training Marquardt and Kearsley 1999 In the past fifty or so years their wide spread use in industry has exploded This increased use and reliance on simulators has been due in part by the advent of the computer iv
20. Manuals Manuals for International Markets pp 19 38 3 Edition Boca Raton CRC Press 46 Robinson P amp Etter R 2000 Structuring the Manual In Writing and Designing Manuals Operators Manuals Service and Maintenance Manuals Manuals for International Markets pp 39 64 3 Edition Boca Raton CRC Press Rothwell W amp Benkowski J 2002 Determining and Using Delivery Methods In R Taft Ed BUILDING EFFECTIVE TECHNICAL TRAIING How to Develop Hard Skills Within Organizations pp 192 217 San Francisco Jossey Bass Pfeiffer Rothwell W amp Benkowski J 2002 Basic Principles of Instructional Systems Design In R Taft Ed BUILDING EFFECTIVE TECHNICAL TRAIING How to Develop Hard Skills Within Organizations pp123 142 San Francisco Jossey Bass Pfeiffer Schank R 1997 Rules to Learn By In VIRTUAL LEARNING A Revolutionary Approach to Building a Highly Skilled Workforce pp 41 51 New York McGraw Hill Welcome Industry Partners Retrieved April 5 2003 from GCM University of Wisconsin Stout Web site n d at http www gcm uwstout edu industry htm APPENDIX A CONSENT FORM 47 48 Consent Form Student Survey for University of Wisconsin Stout UW Stout Graphic Communications Management Programs use of the PackSim Gravure Press Simulator Training Manual This research examines the feeling and reactions of the GCM Program students use of a training manual for the Pa
21. OPY VS COLOR OK gt CT Wo cmm RETURN TO SHOP FLOOR DENSITOMETER GEAR HEAD TAIL OPERATOR VIEW MOVEMENT TOWARDS Figure 1 15 Web View 64 7 The Web Viewer Figure 1 15 shows the printed web during production The Web Viewer screen updates every 5 seconds but the mouse must be over the print copy to view the updated image This is especially important when troubleshooting print quality problems In the Web Viewer label tags for the icons appear in the left bottom corner of the Web Viewer when the mouse is scrolled across the icons Use of the Web Viewer and its icons will be defined in Chapter 2 65 Chapter 2 Get the Press Up and Running The following steps and icons are used to get the press up and running 1 Start the computer using the following steps 2 a Turn the computer Press button on CPU al b Turn on both monitors Press button on both monitors 0 0 The computer w ill b up opening to the Windows start up ae desktop 2 Double click the PackSim icon on the desktop to launch the simulator application lt gt Packsim The PackSim Main Screen will come up see below 3 Click on the Press Room icon M This will bring up the following screen after a short wait 66 Figure 2 1 Press Room View unwind view Scrolling the mouse across the press room Figure 2 1 will highlight various components of the press and allow you to i
22. can be controlled by using the plus or minus buttons in the Speed Window of the Main Control P Set Speed or set Speed window and use the ramp up feature 73 10 Once the press is up and running look through the functions on the Web Viewer Figure 2 8 The Web Viewer screen updates every 5 seconds but the mouse must be over the print copy to view the updated image This is especially important when troubleshooting print quality problems CHOOSE WEB VIEWER POSITION PRINT COPY FULL SIZE VIEW QUARTER SIZE VIEW SIXTEENTH SIZE VIEW GO FROM SPLIT CREEN TO FULL SCREEN VS COLOR OK RETURN TO SHOP FLOOR DENSITOMETER GEAR HEAD TAIL OPERATOR VIEW MOVEMENT TOWARDS Figure 2 8 Web Viewer 11 Moving the cursor over an icon in the Web Viewer will bring up a label tag in the left bottom corner identifying that icon 74 Figure 2 9 Good Web Form View A good copy should look like the press form in Figure 2 9 If you are not getting a Thumbs Up bl check the printed results on the Web Viewer Web Viewer icons and their functions G 00088 cmm o suno o com CO 8 umm ne aaa r SL AAA ess ue Y umm m o e o ee ee Operator Figure 2 10 Web Viewer 75 _ 2 11 Web View position icon 12 Clicking on the Web View icon Figure 2 11 allows you to view the web after individual units See Fig
23. chniques in Chapters 1 3 of this manual Step5 Upon completion of the exercise the following information window will appear click OK See Figure 3 10 Information End of exercice Do you want to quit PACKSIM Figure 3 10 End of Exercise 2 The second exercise is on a Doctor Blade See Figure 3 11 88 DIRECTORIES i COURSES Decurler DoctorBlade Dryer eccentric ESA Exceptions vg EXERCISES Doctor Blade Angle Too Sharp gt CHT Doctor Blade Angle Too Sharp gt CLO Doctor Blade Angle Too Sharp gt DRG Doctor Blade Angle Too Sharp gt SCR Doctor Blade Damaged gt LNS Doctor Blade Damaged by print cylinder gt LNS Doctor Blade Not Parallel to Cylinder gt HAZ v Course gt DoctorBlade Exercise Doctor Blade Damaged gt LNS Your Name j p MAPS M Peces rry EX Figure 3 11 Doctor Blade Exercise _ i s amp 10 42 Step 1 Click on Doctor Blade in the Courses window See Figure 3 11 Step 2 Click on Doctor Blade is damaged gt LNS in the Exercises window See Figure 3 11 Step 3 Type in your name in the space provided See Figure 3 11 Step 4 To start the exercise click on the icon For assistance in exercise resolution refer to Information and techniques in Chapters 1 3 of this manual Step 5 Upon completion of the exercise the following information window will app
24. ckSim gravure printing press simulator The study will use a questionnaire that you will complete after using the manual with the simulator Before completing the questionnaire we would like you to read and then sign the consent form indicating that you understand the potential risks and benefits of participation and that you understand your rights as a participant If you have any questions please contact Jerrold Addie the primary researcher at 715 232 1254 RISKS There is little or no risk to you in filling out this questionnaire Your responses are not identifiable and completed questionnaires will only be used for their raw data by the researcher BENEFITS Although the results of this study may be of benefit to others in the future there is no direct benefit to you by participating in this study CONFIDENTIALITY OF RESPONSES Your answers are strictly confidential There are no identifying marks or codes and only the researcher will have access to the raw data RIGHT TO WITHDRAW OR DECLINE TO PARTICIPATE Your participation in this study is entirely voluntary You may choose not to participate without any adverse consequences to you Should you choose to participate and later wish to withdraw from the study you may discontinue your participation at that time without incurring any adverse consequences NOTE Questions or concerns about participating in the research or subsequent complaints should be addressed to Jerrold Addie th
25. dentify each individual item Clicking on a highlighted area will open another window for that item with further options available to you Figure 2 2 Main Control Panel 4 Clicking on the Main Control Panel icon Figure 2 2 will open the main control panel view Figure 2 3 67 Job Standard Reel To Reel Configuration Sched Prod f min Sched Time Actual Time 12 43 Good 0 ft Waste 0 ft S JOB Set Speed PROD E HELP HISTORY Web Viewer Imp Rollers UP DOWN Web Break Detector wa PANTUNT REWIND CONDITION SETTINGS UNWIND Figure 2 3 Main Control Panel Press Stopped 5 Within the Main Control Panel are a number of buttons and icons that will take you to various press panel views Figures 2 4 amp 2 5 identify the buttons and icons on the above Main Control panel 68 DRIVE PANEL INFORMATION BOX CHECK PRINT i JOB OK X JOB DETAILS Job Standard el To Reel Configuration Sched Time Actual Time 12 53 Sched Prod ft min Good ft Waste ft PRODUCTION STATUS Set Speed HELP Web Viewer PRINT Imp Rollers UP DOWN HISTORY Web Break Detector RETURN TO THE VIOUS SCREEN RETURN TO THE PRESS ROOM Ewes i WEB 5 VIEWER REWIND PANEL WEB PRINT UNIT PRESS REGISTER PANEL CONDITION SETTINGS SETTINGS PANEL PANEL PANEL PANEL Figure 2 4 Main Control Panel Controls 69 6 Figure 2 4 Main Control Panel at the top of this panel is an in
26. e pilot testing of the manual and a follow up survey questionnaire given to Graphic Communications Management program students at UW Stout The survey was developed to gain feedback from the respondents piloting the PackSim training manual to ascertain and improve the manuals usability The survey questionnaire Appendix B was designed and administered to students enrolled in GCM courses at UW Stout The survey contained a total of 14 questions 9 closed ended and 5 open ended using dichotomous polychotomous likert scale and subjective question types A total of 20 surveys were given out to students in class and 8 surveys returned for a response rate of 40 percent Results of the survey will be utilized to improve modify and update the manual to increase its usability 41 Major Findings The feedback from the surveys was overall very positive In the review of literature Robinson and Etter 2000 state People read different manuals in different ways depending on the products If they think the product is simple and shouldn t need or they don t want there to be instructions they may not read them at all This was demonstrated in the results of the survey In the question whether the respondent reviewed the training manual prior to the pilot testing almost two thirds 62 5 responded with no opinion or disagreed that they would review the manual first All 100 of the respondents found the figures in the training manual to
27. e final PackSim gravure printing press simulator training manual will be incorporated into the GCM curriculum for use in future classes Pilot Testing Pilot testing of the training manual will be the method of evaluation and assessment Voluntary participants will be asked to use the training manual to shake it out and then to complete a survey The information from the survey will be used to evaluate the manual s effectiveness and validity The participants will not have had any prior exposure to the PackSim simulator before participating in the study Information obtained will be used to improve modify and update the manual to increase usability The pilot testing will cover these areas of the simulator 1 Introduction to simulator usage 2 Common controls and their functions 3 Getting started a walk through of getting the simulator up and running 4 Discovery of the many panels and controls of the simulator 5 Exercises and Troubleshooting 26 Selection of Subjects All subjects for the pilot testing and survey will be University of Wisconsin Stout students enrolled in the Graphic Communications Management program Press Systems course All subjects will be asked to give their consent to be voluntary participants in this study The sample size is expected to be 15 20 depending on class size and participants willingness Upper class students should be honest and upfront with feedback Yet from this size enough knowled
28. e researcher at 715 232 1254 or Dr James Tenorio at 715 232 1267 Questions about the rights of research subjects can be addressed to Susan Foxwell Human Protections 49 Administrator UW Stout Institutional Review Board for the Protection of Human Subjects in Research 11HH UW Stout Menomonie WI 54751 phone 715 232 2477 I attest that I have read and understood the above description including potential risks benefits and my rights as a participant and that all of my questions about the study have been answered to my satisfaction I hereby give my informed consent to participate in the research study Signature Date Appendix B SURVEY INSTRUMENT 50 51 GCM PackSim Survey University of WI Stout Graphic Communications Program GCM Purpose of survey The purpose of this survey is to develop a usable training manual for the PackSim simulator Being a participant in this survey a request was made for you to also participate in the testing of the PackSim training manual We are collecting the survey information to revise and rework the training manual to make it a more useable product for students to operate and learn from the PackSim simulator Survey Instructions Prior to starting this survey please read and sign the consent form which was given to you separately In order to remain anonymous please do not put your name on this survey Please put the completed surveys in the blank envelope provided and leave
29. e study have you used the PackSim of simulator Respondents Yes 0 0 No 8 100 The results of this question shows that respondents had not had any prior exposure to the PackSim gravure printing press simulator This response relates to the rest of the questions all of the responses come from respondents learning and trying the simulator for the first time Any prior knowledge will not be a barrier to determining if the self directed manual is an effective method to use Table 3 Question 3 Review of training manual I reviewed the training manual prior to starting the of testing Respondents Strongly Agree 1 12 5 Agree 2 25 No Opinion 2 25 Disagree 3 37 5 Strongly Disagree 0 0 Total 8 100 The results showed that more than half 62 5 either had no opinion or disagreed that they reviewed the training manual prior to starting the pilot of the 33 training manual on the simulator This was not an unexpected result as the literature review shows that many people try first and look only when they have questions or run into problems they cannot solve Table 4 Question 4 Find the manual useful I find the manual useful of Respondents Strongly Agree 2 25 4 50 No Opinion 2 25 Disagree 0 0 Strongly Disagree 0 0 Total 8 100 The results of this question show that the respondents agree 75 that the self dir
30. ear click OK See Figure 3 12 89 Information E3 End of exercice Do you want to quit PACKSIM Figure 3 12 End of Exercise 3 The third exercise is Ink Viscosity See Figure 3 12 DIRECTORIES COURSES InkApplicator InkFeedPum EXERCISES Viscosity Too Low gt CLO DRG Viscosity Too Low gt CLO OFS Viscosity Too Low gt CLO PIK Viscosity Too Low gt CLO STC Viscosity Too Low gt CLO VOL Course InkViscosity Exercise Viscosity Too Low gt CLO HAZ Your Name j 2 PSP M Pays jury EXIT Figure 3 12 Ink Viscosity Exercise Step 1 Clicking on Ink Viscosity in the Courses window See Figure 3 12 Step 2 Click on Viscosity Too Low gt CLO HAZ in the Exercises window See Figure 3 12 90 Step 3 Type in your name in the space provided See Figure 3 12 Step 4 To start the exercise click on the icon For assistance in exercise resolution refer to Information and techniques in Chapters 1 3 of this manual Step 5 Upon completion of the exercise the following information window will appear click OK See Figure 3 13 Information Ed End of exercice Do you want to quit PACKSIM Figure 3 13 End of Exercise 9 To end program after the exercises select the Exit icon in the Press Room Then select Exit icon from Courses and Exercises Then select Exit icon from the PackSim Main Control Screen to exit the program P
31. ected manual is useful This is a strong showing considering that most manuals do not get used and are notorious for being ineffective Table 5 Question 5 Chapter layout useful I found the Chapter layout useful to find helpful of information during simulator usage Respondents Strongly Agree 0 0 Agree 6 75 No Opinion 1 12 5 Disagree 1 12 5 Strongly Disagree 0 0 Total 8 100 34 The overwhelming majority 75 found the manual s layout helpful and useful to them during the pilot testing of the simulator This question was asked to determine if the manual s layout worked as designed Table 6 Question 6 Notes provided The notes provided useful tips of Respondents Strongly Agree 1 12 5 5 62 5 No Opinion 1 12 5 Disagree 1 12 5 Strongly Disagree 0 0 Total 8 100 This question was asked to find out if the respondents found the notes to provide needed information An overwhelming majority strongly agreed or agreed 75 that the notes provided useful tips in the operation of PackSim gravure printing press simulator 35 Table 7 Question 7 Figures The figures helped in using the simulator of Respondents Strongly Agree 3 37 5 5 67 5 No Opinion 0 0 Disagree 0 0 Strongly Disagree 0 0 Total 8 100 With this question there was unanimous 100 agreement that the figures i
32. ed offset heat set web offset gravure and flexography UW Stout s GCM program has Sinapse s wide web offset gravure and flexography simulators These simulators presently do not have any self directed training manuals that can be used by the GCM students and is the basis for this study UW Stout s GCM program uses a combination of hands on practical application along with traditional classroom teaching to cover most aspects of the printing industry In areas where hands on experiential training is not possible or impractical simulators can be of great benefit Sinapse s PackSim gravure printing simulator provides GCM students at UW Stout another opportunity to widen their horizons Simulator Training Methodology Traditional instruction methods are not the method of choice when it comes to the use of simulators The use of simulators for learning in the workplace has emerged from a practical need to provide hands on practice Unlike other instructional methodologies it has not developed historically from theories of learning or teaching As simulations have come to be 15 used more broadly however greater attention has been paid to the underlying theoretical basis Marquardt and Kearsley 1999 The delivery of training is made easier with the use of the simulator as is becomes the training instrument Computers have also aided this as they have made emulation of the process or task possible in a self contained module or
33. ess simulator to be incorporated into the curriculum of the Graphic Communications Management program at UW Stout The results of the study will be a self directed training manual for GCM students to follow while they use the simulator Student participation will include pilot testing the manual and completing a survey questionnaire Appendix B asking students feedback on the usefulness of the manual This information will be collected and utilized to make the final manual a better product for future users The revised training manual will give the GCM program a user friendly way of teaching gravure via the PackSim gravure printing press simulator Students from the GCM program voluntarily participated in the pilot testing of the training manual and completed the survey instrument This chapter reports the findings and analysis of the survey instrument None of the GCM student respondents had any prior exposure to the PackSim gravure printing press simulator 30 Statement of the Problem UW Stout GCM program has no self directed training manual to operate the Sinapse s PacSim gravure printing press simulator The purpose of this study is to develop a training manual for the PackSim simulator Survey Instrument The survey questionnaire Appendix B was designed and administered to students enrolled in GCM courses at UW Stout The survey contained a total of 14 questions 9 closed ended and 5 open ended using dichotomous polychotomous
34. following compilation is a list of how manuals are perceived and utilized People will use manuals only if the input meets or exceeds the effort Do they get something for their time e People read with memory their past encounters with instructions shape their present experience People almost always would rather ask a person than read a text 18 People read only if they can t get information another easier way and they read as little as possible People read a manual while doing something else working with the product This simultaneous activity is crucial to understanding how to design a manual to help a user Many many people are reading to use a product on the job They are not reading for fun they are reading only to use a product to get something else done A manual and a product for that matter should be a service not a hardship for the user People are often in a hurry under stress anxious or at least uncertain when they pick up a manual particularly if the product is unfamiliar to them or appears to be technically sophisticated or involves software of any kind People read different manuals in different ways depending on the products If they think the product is simple and shouldn t need or they don t want there to be instructions they may not read at all 19 People with experience in reading manuals are optimistic readers they will pick and choose what they want to read one e
35. formation box see Figure 2 4a that supplies updated information on the production job Job Standard Reel To Reel Configuration Sched Time Actual Time 11 20 Sched Prod ft min Good 1158 ft Waste 0 ft Figure 2 4a Information Box 7 The Help button E gives you a screen see Figure 2 4b that provides information on the job any faults occurring and possible causes of the faults Job Standard Reel To Reel Configuration Sched Time Actual Time 11 25 Sched Prod ft min Good 3171 ft Waste 0 ft Print faults Incomplete transfer of ink from cells Missing print Copy faults All faults The substrate is too absorbant The substrate moisture content is too high The cells on the print cylinder have been engraved or etched too deeply The print cylinder is extreemly worn Some of the cells on the print cylinder are blocked The celle the nrint evlinder are nnt deen ennuah lt Definitions Causes WEB PRINT UNIT NT nen CONDITION SETTINGS EEEH UNWIND Figure 2 4b Help Screen Main Control Panel 70 CURRENT DECREASE INCREASE FORMALION SPEED SPEED SPEED BOX Sta card Reel To Reel Configurat in Sq ed Time actual Time 12 43 MAIN POWER Sched Prod Good D ft faste ft Set Speed WEB VIEWER Web Viewer Z2 LOW RAMP Imp Rollers UPIDQV A ACCELERATOR Web Break Detector WEB BREAK 7 DETECTOR WEB PRINT UNIT CONDITIO SETTINGS
36. ge will be gained to assess the usefulness of the training manual Laboratory Procedures Written procedures on the testing of the pilot manual will accompany the draft copy of the training manual Each participant will be asked to sign a copy of the consent form Appendix A and given a copy of GCM PackSim survey questionnaire Appendix B Each participant will be asked to use the PackSim simulator following the training manual At the end of the pilot test participants will be asked to complete and turn in their surveys they will be provided blank envelopes to turn in their survey to retain their anonymity The questionnaire surveys will be used to verify if the procedures in the manual are specific correct and clear enough for the user to follow 27 Evaluation and Analysis After the completion of the pilot testing and collecting the survey the researcher will evaluate the responses Questions that use a likert scale will be evaluated using percentage of respondents that answer that particular area Significant differences in agreement on these questions will be impetus for possible inclusion omission or restructuring the PackSim gravure printing press simulator training manual The open ended survey question results will be analyzed comments will be sorted for commonality and multiple concerns or problems will be analyzed to determine if change would eliminate or strengthen an area of contention Any area of change that is necessita
37. gh a training module of the simulator The pilot testing of the manual by the GCM students will encompass simulator familiarization controls functioning of the controls control panel recognition problem resolution and starting and operating the press The questionnaire survey provided to the students will enable the researcher to determine the validity of the training manual 24 Methods The researcher will use one of the instructional systems design ISD models to design the training manual Instructional system design ISD was invented by the U S military as an efficient and effective way to train soldiers Rothwell and Benkowski 2002 The model to be used is the ADDIE model The parts of the model are Analyze Design e Develop Implement e Evaluate The word ADDIE is an acronym formed from the first letter of each word above Rothwell and Benkowski 2002 The first part of the ISD model is to analyze with a needs assessment In the case of the PackSim simulator there is a need as this simulator is new technology being incorporated into the GCM curriculum The PackSim gravure printing press simulator training manual will use elements of design and development to build the training manual that will be part of the pilot testing 25 Implementation of the training manual will occur during the pilot testing Assessment and evaluation will be used to determine the final structure of the training manual Th
38. he program The simulator can run using either one or two monitors If running with only one monitor you will not be able to view the web and control panels simultaneously UW Stout s default simulator system uses two monitors The two screen selection is the preferred method When running the simulator in the one screen option an icon becomes available clicking on this takes you to the web viewer In the two screen option this icon is not displayed 60 29 L EM Figure 1 7 Press Room View unwind view From the Press Room View scrolling the mouse over the room will highlight certain components by clicking on the highlighted areas new screens will appear The use of these screens will be explained in Chapter 2 Icons used in the Press Room window are illustrated below Figure 1 8 Viewing Booth icon 1 Clicking on the Viewing Booth icon Figure 1 8 will open up the quality control window Within this window there are two options available blocking adhesion and solvent retention Clicking on either option and then clicking check will open another window These are checks that deal with ink and substrate or if there is a solvent retention problem Figure 1 9 Web Path icon 61 2 Clicking on the Web Path icon Figure 1 9 opens its option window From here you can highlight both WebPath and Condition then click on the check button to reveal the web path condition Clicking the check button it will state
39. in order but actually we were just supposed to read them Starting the press e No comments Exercises Some features in exercises were not covered so the operator had to use a lot of trial and error The last exercise I had everything done But would not end the exercise I had to quit the program and repeat the last exercise Question 11 List any instructions that were unclear or missing None e It allows you to start the press and tells you which assignment to do however finding where the panels are to change viscosity ESA ect I had to find my own Question 12 Did the format of the manual help or confuse you Explain e It kind of confused me just because I didn t know when I was supposed to try everything Help Placement of images along with instructions was beneficial 38 e Format was helpful and clear e Helped Help it was linear and definitely helps to get started Question 13 How could this manual be improved to make it better e Less intro Too wordy e Certain images are blurred Correct typos Put the lesson more in the middle not at the end I didn t understand what I was supposed to do at first e Discuss where individual sections needed for the exercises are found Explain the different buttons briefly and how to find them Print the booklet on both sides of each page so that more info can be viewed a time Question 14 Did the training manual help you understand the PacSim simulato
40. ion and assessment Voluntary participants will be asked to use the training manual to shake it out and then to complete a survey The information from the survey will be used to evaluate the manual s effectiveness and validity The participants will not have had any prior exposure to the PackSim simulator before participating in the study Information obtained from the pilot testing and completion of the survey will be used to improve modify and update the manual to increase usability vi TABLE OF CONTENTS Table Page Abstract iii List of Tables ix List of Figures X Acknowledgements xi Chapter I Introduction Introduction 1 Simulation History 3 Gravure History 4 Statement of the Problem 5 Purpose of the Study 5 Significance of the Study 6 Assumptions of the Study 7 Limitations of the Study 7 Definition of Terms 8 Chapter II Review of Literature Introduction 11 Simulator Usage 11 vii Computer Based Simulation 12 Printing Press Simulators 13 Simulator Training Methodology 14 Training Manual Development 16 Self Directed Training 20 Chapter III Methodology Overview of Study 21 Description of Research 22 Methods 24 Pilot Testing 25 Selection of Subjects 26 Laboratory Procedures 26 Evaluation and Analysis 27 Methodological Assumptions 27 Restatement of the Problem 28 Summary 28 Chapter IV Finding and Analysis of Results Introduction 29 Statement of Problem 30 Chapter V References Appendix A
41. ip Robinson and Etter 2000 The student will gain the knowledge not only how this particular simulator works but also the gravure printing process behind the simulator Assumptions of the Study The following is a list of assumptions made by this study 1 UW Stout does not have a training manual to step students through the PackSim gravure printing press simulator 2 Participation of a student in both the pilot test and survey is on a voluntary basis 3 UW Stout s GCM program has a need for the manual on the simulator 4 The researcher utilizes the best available method for developing the training manual 5 Lessons exercises used are sound training for gravure Limitations of the Study The limitations of this study are 1 The study involved only students in the GCM Program at UW Stout 2 It covers only one of the simulators made by Sinapse 3 It only covers three lessons exercises of the PackSim simulator 4 Student surveys after pilot testing will be used to define the training manual s final format 5 The GCM students are fundamentally management oriented students they are not equipment operators 6 Time constraints do not allow for multiple pilot testing of the training manual Definition of terms Flexography a rotary letterpress process printing from rubber or flexible plates and using fast drying inks Mainly used for packaging Budgett 1989 Graphic Communications the processes and industries
42. lop a training manual for the PackSim simulator Purpose of the Study The purpose of this study is to develop a self directed training manual for the PackSim gravure printing press simulator to be incorporated into the curriculum of the Graphic Communications Management program at UW Stout The results of the study will be a self directed training manual for GCM students to follow while they use the simulator Student participation will include pilot testing the manual and completing a survey questionnaire asking students feedback on the usefulness of the manual This information will be collected and utilized to make the final manual a better product for future users The revised training manual will give the GCM program a user friendly way of teaching gravure via the PackSim gravure printing press simulator Significance of the Study Development of the self directed training manual will provide the GCM students with the opportunity to apply practical application to the gravure process This is in line with UW Stout s Hands on Minds on Business and Industry 2003 learning philosophy The training manual will provide the students an outline on the basics of the PackSim gravure printing press simulator It will also try to answer the following questions What do I need to do What is this thing How do these two fit What goes where If I do this then what happens What do I do next How long is this going to take What can I sk
43. n the PackSim gravure printing press training manual provided help during the PackSim simulator operation Table 8 Question 8 Instructions The instructions were clear of 9b Respondents Strongly Agree 2 25 Agree 4 50 No Opinion 1 12 5 Disagree 1 12 5 Strongly Disagree 0 0 Total 8 100 This question asked if the instruction were clear 75 of the respondents agreed Only one respondent followed up with the open ended question question 11 that there was some confusion to the instructions Table 9 Question 9 Helpfulness of exercises 36 The manual helped in doing the exercises of Respondents Strongly Agree 4 50 Agree 2 25 No Opinion 0 0 Disagree 2 25 Strongly Disagree 0 0 Total 8 100 This question in conjunction with question number 14 was asked to validate the helpfulness of a self directed training manual This question shows that the overwhelming majority 75 found the manual helpful in accomplishing the exercises on the simulator The following questions 10 14 are open ended and are used to gather further information on the development of a self directed training manual Each question is listed and comments made recorded Duplicate answers are not shown Question 10 Check any parts of the manual that did not work with the simulator Explain Introduction 37 actually thought we were supposed to do the steps
44. ng process If you have problems or questions on the simulator please ask the instructor Exercises The three exercises that you are to complete are as follows 1 Electro Static Assist exercise 2 Doctor Blade exercise 3 Ink Viscosity exercise 1 The first exercise is the Electro Static Assist ESA exercise See Figure 3 9 for exact exercise to run DIRECTORIES COURSES eccentric Exceptions EXERCISES Electro static assist not plugged in gt DRD Electro static assist not plugged in gt DRD CLO The electro static assist charging device is not in the correct positio The electro static assist charging device is not in the correct positio The electro static assist unit is not working properly DRD The electro static assist unit is not working properly gt DRD CLO The power to the electro static assist unit is too high Course ESA Exercise The power to the electro static assist unit is too high gt HAZ Your Name your name n js j a cs er Figure 3 9 ESA Course and Exercise 87 Step 1 Clicking on ESA in the Courses window See Figure 3 9 Step 2 Click on The power to the electro static assist is too high gt HAZ in the Exercises window See Figure 3 9 Step 3 Type in your name in the space provided See Figure 3 9 Step 4 To start the exercise click on the icon For assistance in exercise resolution refer to Information and te
45. nsive downtime The development of a gravure printing press simulator has allowed training of personnel and students without the extreme cost and space required for the actual equipment The philosophy behind Sinapse s PackSim gravure printing press simulator is to give the user the most realistic gravure printing press operating training along with exercises to familiarize the user with day to day problems PackSim aids the operators in identifying and correcting problems and or poor troubleshooting techniques that on an actual press could possibly cost more than the job being printed Although students may use this simulator it was designed with a press operator in mind The PackSim s level of sophistication makes it highly realistic This sophistication may make it difficult for even the seasoned gravure press operator to use the simulator without formal training As with any computer based program a certain amount of training is required to become proficient At present there is not a manual that will aid the novice student through the learning curve required to operate the simulator successfully It is with this in mind that the researcher developed the training manual to aid the GCM student in the use of the PackSim gravure printing press simulator Statement of the Problem UW Stout GCM program has no self directed training manual to operate the Sinapse s PacSim gravure printing press simulator The purpose of this study is to deve
46. on a substrate A gravure press for use in a university is a prohibitive capital investment which many schools cannot 43 afford The use of simulators to take the place of these high cost investments is a logical course of action In the GCM program at UW Stout there is a need for more coverage of the gravure printing process in the curriculum Using the PackSim gravure printing press simulator and the training manual will address this need in the program The pilot testing and survey response prove this is a reasonable alternative to actually having a gravure printing press The military continues to lead the way in the use of simulators However the rest of the world is catching on Future studies of the use of various computer based simulators in educational environments should be considered This study would have benefited if time allowed for pilot testing of the final training manual Future studies at UW Stout could include the Sinapse s heat set web offset wide web flexography narrow web flexography and corrugated flexography computer based press simulators These computer based simulators are how future students will learn new processes 44 References The Collins English Dictionary 2000 Harper Collins Publishers Retrieved April 20 2003 at http www wordreference com English definition asp en simulator Bremer M 2000 Part The Software User Manual all about manuals In The User Manual Manual
47. ormation and tips on how to run the exercise and troubleshoot for problem resolution Each exercise is outlined on what the exercise is and how to start the exercise Problem resolution for the exercise is up to you 58 Chapter 1 Simulator Familiarization The PackSim Simulator uses a number of icons that you need to become familiar with The following is a list of icons and their functions within the simulator Figure 1 1 PackSim Main Control Screen Main Control Screen Icons and their functions M Figure 1 2 Press Room icon 1 Clicking on the Press Room icon Figure 1 2 will take you to the Press Room view See Figure 1 7 The Press Room will be further explained in Chapter 2 Figure 1 3 Courses amp Exercises icon 2 Clicking on the Courses and Exercises icon Figure 1 3 will bring you to the Courses directories window which will be discussed in Chapter 3 59 Figure 1 4 Software Configuration icon 3 Clicking on the software configuration icon Figure 1 4 opens the panel to set monitor options and sound This is already pre set on the simulator A Figure 1 5 Contacts icon 4 Clicking on the Contacts question mark icon Figure 1 5 will take you a list of original contributors to the simulator Figure 1 6 Exit icon 5 Clicking on the Exit icon Figure 1 6 will exit you from the program Exit buttons throughout various screens in the simulator program will allow you to quit and exit t
48. p in determining problem resolution Step 1 In the exercise the press is up and running Check the Web Viewer Figure 3 2 and look for any telltale signs of a problem m 3s Figure 3 2 Web Viewer Step 2 Click on Print Copy Vs Color OK E and look for problems See Figure 3 3 Remember the Color OK is on the right x F Step 3 If you have determined where the problem might be isolated you can look at the affected part of the web Click on the Web Viewer Position to select the section of the web to troubleshoot the problem For example If you think the problem is occurring in unit 3 click on it See Figure 3 4 82 Web view afer C Unit C Unit 4 C Unit 2 C Unit 5 Unit 3 C Unit 6 Web guide C Slitters Cancel Figure 3 4 Unit Selection Figure 3 5 Web View after Selection In Figure 3 5 the Web View of Unit 3 selection in Figure 3 4 is shown From this you can determine if this was the affected printing unit Step 4 Next from the Press Room view Figure 3 6 click ona Printing Unit 1 7 In this example printing unit 3 is shown see Figure 3 7 Figure 3 6 Press Room View 83 Step 5 To troubleshoot the problem scroll the mouse over the pictorial view of the printing unit in Figure 3 7 Select the area that you think is causing the problem clicking on it allows checks and actions to be accomplished See Figu
49. placed on the densitometer and in the left bottom corner the tag label appears get densitometer by moving the cursor over various icons of the Web Viewer will bring up the respective label for that icon 80 Chapter 3 Exercises and Problem Resolution In this chapter you will find three exercises for PackSim Gravure printing press simulator Each exercise is outlined not solved certain parameters are in effect and will be provided to the user to get started on the exercise Some problem resolution techniques are outlined in this chapter Exercise Procedure Problem Resolution Overview 1 To start an Exercise click on the Exercise icon This will bring up Figure 3 1 ee DRECTORIES COURSES Viscosity Too Low gt CLO HAZ Your Name yourname u PAIS irri eu f BALE TU Figure 3 1 Select Exercise Window Note The Select Exercise Windows Figure 3 1 has numerous options available to you The exercises you will work on and the options you will use will be spelled out for you later in this chapter under the exercises section 2 Once the selection of an exercise is made type in your name in the space provided 3 Then to start the exercise click on the icon 81 The exercise will give a description of the problem upon start up This description will give you hints on what and where to start the problem resolution process 4 Once the exercise is started use the following steps to hel
50. qually important what not to read People do not deliberately set out to read poorly or use the product ineptly or unsafely as Lila Laux human factors expert with U S West Technologies points out Robinson and Etter 2000 The advantages to having a manual must outweigh the disadvantages In the case of the PackSim simulator the complexity of its operations allows it to simulate a multitude of real world problems on the gravure printing press A manual must deal with the simulators complexity and provide enough information and insight to allow the student to operate the simulator successfully Simulations can be effectively used to build knowledge of processes and skills in procedural and principle based tasks Clark 1999 With Clark s thoughts in mind the PackSim training manual is built to be user friendly and simple in design yet effective 20 Self Directed Training Self directed training ranges in many forms from paper based materials to computer based training CBT modules Computer based simulation This is often overlooked as a vehicle for self directed learning but is a very effective method of learning Harrison 1999 An advantage of self directed training is that students can use a training manual and cover the learning on a computer based simulator on their own time The only learning which significantly influences behavior is self discovered self appropriated learning McNamara 2003 A disadvan
51. r operation Yes e Yes it did The exercises we did were fun and helpful e Yes but most of all it was actually using the simulator 39 Chapter V Summary Conclusions and Recommendations Summary The purpose of this study is to develop a self directed training manual for the PackSim gravure printing press simulator to be incorporated into the curriculum of the Graphic Communications Management program at UW Stout The results of the study will be a self directed training manual for GCM students to follow while they use the simulator Student participation will include pilot testing the manual and completing a survey questionnaire asking students feedback on the usefulness of the manual The information obtained from the completed surveys will be used to make changes additions and deletions to be incorporated in the final revision of the PackSim training manual The final version of the PackSim manual will be utilized in the GCM program curriculum Restatement of the Problem The purpose of this study is to develop a training manual for the PackSim gravure printing press simulator for use in the University of Wisconsin Stout s 40 Graphic Communications Management program Presently there is not a manual available for the students to accomplish self directed training on the PackSim simulator Methods and Procedures Research for this study was accomplished by information gathered through the review of literatur
52. re 3 8 as an example Figure 3 8 Select Checks and Actions By making selections on differing areas of Figure 3 8 allows you to make checks and take appropriate action In order for you to accomplish an action the press must be STOPPED Step 6 Another area in problem resolution is at the Main Control Panel See Figure 3 9 At the Main Control Panel clicking on the Printing Unit Setting takes you to the Print Unit Control Panel See Figure 3 10 84 Job Standard Reel To Reel Configuration Sched Time Actual Time 12 43 Sched Prod Good D ft Waste 0 ft Set Speed Web Viewer Web Break Detector e Figure 3 9 Main Control Panel Job The power to the electro static assist unit Sched Time Actual Time 11 21 Sched Prod Good 48 ft Waste 56 ft DRYER VISCOSITY ESA Temp Zonel Temp Zone 2 Actual Voltmeter 3 Air Flow Zonel Air Flow Zone 2 Exit Web Temperature LEL Power Impression 7CTTEYT TE Figure 3 10 Print Unit Control Panel Step 7 The Print Unit Control Panel Figure 3 10 there are a number of controls that you should look at and consider during 85 problem resolution These controls are Dryer Viscosity and Electro Static Assist ESA controls Also on the bottom of the Print Unit Control Panel is a pictorial view of the press From this view you can change which printing unit you are viewing 5 The exercises use a
53. roduction Introduction The University of Wisconsin Stout is one of the thirteen four year campuses in the Wisconsin of University System UW Stout s Graphic Communications Management GCM program started as a printing program in the early 1900s It was created to prepare secondary teachers in the area of printing Brendel DeCaria and Kochnowicz 1999 From this humble beginning as an Industrial Arts School Stout grew in prominence to a premiere four year university UW Stout s approach remains true to its motto of Hands on Minds on Business and Industry 2003 learning This lab oriented approach to learning is the great distinguisher between UW Stout s GCM program and other Bachelor s degree printing programs The GCM program is one of the top programs in the country that is preparing Bachelor s degree level human resource talent for the printing and publishing industries Welcome Industry 2003 It is in this tradition that the researcher developed a training manual in line with the objectives and goals of the GCM program In order for the GCM program to continue to push the technological envelope it must keep up to date with new equipment However the cost is extremely high with scarce resources available Most difficulty is in the press area Fortunately the program has been able to stay current through competitive purchasing and donations of equipment and supplies The need for ways to demonstrate each of the
54. rposes of research or operator training example space simulator Collins Dictionary 2000 Substrate Any material with a surface that can be printed or coated Prust 2003 Web A continuous roll of printing paper used on web fed presses Budgett 1989 10 DOCTOR BLADE IMPRESSION SCRAPPING CYLINDER EXCESS INK FROM PAPER SURFACE INK CELLS PRINTING CUT IN CYLINDER CYLINDER INK TROUGH Figure 1 1 Gravure printing process Mardle 2003 DOTOR BLADE IMPRESSION WIPING EXCESS INK THER FROM SURFACE PAPER INK CELLS PRINTING CUT IN CYLINDER CYLINDER INK PAN FOUNTAIN Figure 1 1a Revised version of Gravure printing process Mardle 2003 11 Chapter II Review of Literature Introduction The Graphic Communications Management program GCM at the University of Wisconsin Stout uses a hands on minds on Business and Industry 2003 approach to learning The use of the PackSim gravure printing press simulator will assist the GCM student s in learning the gravure printing process The literature review will cover simulator usage computer simulation and Sinapse s PackSim Gravure simulator along with producing and using a training manual Simulator Usage Simulations can be effectively used to build knowledge of processes and skills in procedural and principle based tasks Clark 1999 Simulators can be used to train simple or complex processes
55. s expertise Capturing and 13 integrating expert knowledge into the computer simulation is something every company can do Schank 1997 Computer based simulation provides pilots the opportunity to fly without leaving the ground Flight simulators have advanced to the point where they are used during accident investigations to recreate flight conditions occurring during the flight mishap When one thinks of computer simulation he she can think of computer games A lot of games are no more than simulators disguised to be fun and provide entertainment Even games are used in training More recently the Marine Corps has developed training games that run on networked laptops That feature allows the Marines to practice a variety of combat roles pilots riflemen tank drivers and maintain their skills even while on ship Macedonia 2002 As times have changed students come to college with a different set of learning skills Today s college age generation is much more astute in skills necessary to operate computer based simulators Printing Press Simulators Printing press simulators were developed to aid in training operators on the press procedures and troubleshooting A press simulator allows the user to develop skills needed to operate the equipment without the expense of costly mistakes on actual equipment A French firm Sinapse has developed a number of 14 computer based printing press simulators such as sheet f
56. self directed training manual can answer the students questions of how what why Training Manual Development One of the advantages to the self directed PackSim gravure printing press simulator training manual is user friendly to assist the student along with the PackSim computer based simulator program It is used as a guide and reference for the user to find his her way through the simulator s programming When simulations are developed for instructional purposes they tend to reflect many systems design assumptions and concepts Marquardt and Kearsley 1999 It is with this thought in mind that the training manual development for the PackSim 17 gravure printing press simulator program must include familiarization of program components operating characteristics features exercises and problem resolution However before the training manual development starts research on how manuals are used provides valuable insight to consider when writing the manual Technical manuals especially software manuals have generally dismal reputation Most people ignore or avoid them Bremer 1999 Users want clear information that will help them solve their problems or answer their questions as they use a product They also want to save face Robinson and Etter 2000 Prior to building a manual there is a certain amount of planning required One of the questions that need to be answered is how will the manual be used The
57. tage to self directed training is the individual s level of motivation if low it can present a barrier to learning or accomplishing the training objectives 21 Chapter III Methodology Overview of Study The purpose of this study is to develop and pilot test a training manual for the PackSim gravure press simulator for use in the University of Wisconsin Stout s Graphic Communications Management GCM program The GCM program is starting to develop curriculum to utilize a number of simulators in printing press processes This training manual will allow the GCM program to incorporate the PackSim gravure press simulator into its curriculum as a self directed training module There are various ways of instructional delivery available to deliver information to the student It is no different in the world of self directed computer based applications Designing a stand alone computer based training CBT module can be accomplished for any number of learning training functions Most CBT modules will walk the user through the operational use of the module However in the case of the PackSim computer based simulator there is no operational module The PackSim simulator is a very complex program 22 requiring some form of training in order for the user to operate it The need for training manual is evident in the GCM program The researcher will discuss 1 How best to develop a simulator training manual 2 What is the best methodology
58. ted through the evaluation of the survey instrument will be incorporated in the final revision of the PackSim training manual This final evaluation stage in the ISD model is necessary to bring validity to the training manual development process Methodological Assumptions It is the assumption that a self directed manual is an effective method of training students on the use of the PackSim gravure printing press simulator The review of literature confirms that a training manual is best suited to this form of 28 training with the simulator It is also assumed that a completed manual will be put into use in the curriculum of the GCM program Restatement of the Problem The purpose of this study is to develop a training manual for the PackSim gravure printing press simulator for use in the University of Wisconsin Stout s Graphic Communications Management program Presently there is not a manual available for the students to accomplish self directed training on the PackSim simulator Summary This chapter covers the methodology used in developing and pilot testing a self directed training manual for the Graphic Communications Management program at the University of Wisconsin Stout The use of a survey to evaluate the process of development is also utilized 29 CHAPTER IV Findings and Analysis of Results Introduction The purpose of this study is to develop a self directed training manual for the PackSim gravure printing pr
59. tudy Materials pp 203 232 New York McGraw Hill Kipphan H Ed 2001 Explanation of Specific Terms IN Handbook of Print Media pp 1115 1124 Berlin Heidelberg New York Barcelona Hong Kong London Milan Paris Singapore Tokyo Springer Macedonia M 2002 March Games Soldiers Play IEEE Spectrum Online Retrieved April 1 2003 at http www spectrum ieee org WEBONLY publicfeature mar02 mili html Mardle Frank n d COLLECTNEWS Stamp Collecting Retrieved April 5 2003 at http www 1840on com HELP 20ABOUT 20STAMP 20PRINTING 20GR AVURE HTM Marquardt M amp Kearsley G 1999 Simulation Simulators and Virtual Reality In Technology Based Learning Maximizing Human Performance and Corporate Success pp 131 141 New York St Lucie Press McNamara C n d Strong Value of Self Directed Learning in the Workplace How Supervisors and Learners Gain Leaps in Learning Retrieved March 6 2003 at http www mapnp org library trng dev methods slf drct htm Moore Kevin 2002 December 17 A Brief History of Aircraft Flight Simulation Retrieved April 4 2003 at http www bleep demon co uk SimHist1 html Prust Z A 2003 Glossary of Technical Terms In Graphic Communications The Printed Image pp 559 590 Tinley Park IL Goodheart Wilcox Robinson P amp Etter R 2000 Analyzing the Manual Users In Writing and Designing Manuals Operators Manuals Service and Maintenance
60. ure 2 12 In this window you can select the section of the web to view by clicking the appropriate circle next to the unit listed Web view afer Figure 2 12 Unit Selection Figure 2 13 Full Size View icon 12 Clicking the Full Size View icon Figure 2 13 gives you the full view of web See Figure 2 10 Figure2 14 Quarter Size View icon 13 Clicking the Quarter Size View icon Figure 2 14 allows you to select a section of the Web Viewer and enlarge that area See Figure 2 15 76 M AO y 3 We m Y of PM D MS Figure 2 15 Quarter Size view of Web Viewer Figure 2 16 Sixteenth View icon 14 Clicking the Sixteenth View Figure 2 16 allows you to select a section of the Web Viewer and enlarge that area See Figure 2 17 Figure 2 17 Sixteenth View Figure 2 18 Magnifier icon 15 Clicking the Magnifier Figure 2 18 allows you to select a section of the Web Viewer and magnify the portion you desire to look at See Figures 2 19 and 2 20 77 Figure 2 19 Magnifier Target Figure 2 20 Magnified View Figure 2 21 Strips View icon 16 Clicking the Strip View Figure 2 21 allows you to view both color bars and register targets on both the operator and gear side It is viewed with the Color OK for comparison against the current production copy Figure 2 22 Split Screen to Full Screen icon 17 Clicking on the Split Screen to Full Screen View icon Figure 2
61. x problems that happen in the every day world of printing The purpose of this Training Manual is to provide the UW Stout GCM students the opportunity to learn the gravure printing process This manual is separated into three chapters 1 Simulator Familiarization 2 Get the Press Up and Running 3 Exercises and Problem Resolution 57 Overview The following are some general instructions on how to use and follow this manual 1 Chapter 1 covers the Main Control Screen and Press Room icons of the simulator Each icon is explained as to what its use is This is to familiarize you with some of the basic functions of the simulator and what happens when you click on that particular icon Reviewing this information will help with accomplishment of the exercises 2 Chapter 2 covers getting the press up and running This includes turning on the computer and monitors along with selecting the PackSim simulator When the simulator is selected there is a number of panels that can are used in running the press this chapter covers these panels and their related functions Once the press is up and running utilizing the various icons and control panels you can learn what a properly set up and operating gravure press looks like This knowledge will aid you when troubleshooting the exercises 3 Chapter 3 covers exercises and problem resolution The first part of the chapter provides an overview of the exercise procedures This is informative inf

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