Línea de envasado parada

A 90-minute, 4-round basic Express simulation for Spanish vocational training (Formacion Profesional), module 0955 Montaje y mantenimiento de lineas automatizadas of the Tecnico en Mantenimiento Electromecanico (Real Decreto 1589/2011). The learner is Ainhoa Echegoyen, a newly qualified electromechanical maintenance technician at a fictional juice plant, Zumos Valdecerrada, between October 2027 and September 2028.

Four situations set the packaging line's course: the case packer stopped with three alarms on its HMI, and how the machine is made safe (main switch padlocked, air dumped, head blocked, a start tried; Real Decreto 1215/1997 annex II 1.14) and how the alarms are read (the first alarm, its time and its step before anything is acknowledged); the labeller that loses the bottles and the slow pneumatic head, and how the photocell's signal is followed along its chain and what is done with the pneumatics (pressures, leaks, valve and sensors against the diagram); the palletiser stopped at a step without an alarm, and how the PLC program is read (online in monitoring only) and in which order the tests are done (by hypotheses); and the annual review, with the work order in the GMAO and the close of each stop.

Three critical errors cap the round: a guard switch defeated, an input forced in the PLC, an interlock removed from the program. KPIs: stops resolved right first time, cost of the stops, time to repair per stop and parts changed without need. Spanish primary, English parity. Fictional companies and people; real regulations and curriculum cited.

An introductory simulation that assumes no prior knowledge of the subject, designed for undergraduate courses. It also works in vocational and high-school programmes and in onboarding sessions.