Premium Aluminum Producer
North America
VR Training for safety protocols
2022 – 2023
VR Training for safety protocols related to aluminum smelting
About the Customer :
Our client is the world’s largest premium aluminum producer and one of the biggest industrial companies in the United Arab Emirates. They operate several smelters in the Middle East.
Project Requirements:
Aluminum production facilities use carbon anodes that are used to conduct electricity into iron vessels containing alumina, called ‘pots’. The electric energy moving through the anodes starts the smelting process, during which molten aluminum is tapped for further processing. Due to the high voltage and temperatures of the materials involved, ensuring safety throughout the smelting process is of the utmost importance. To facilitate this, our client wanted to convert several of their safety procedures into Virtual Reality, with a focus on their accident response protocols during the movement of anodes into the pots.
XR Labs Solution :
XR Labs delivered an immersive and realistic simulator to the client, built on Unreal Engine 4. The simulation recreated the factory floor of the smelter in VR, and guided employees on important safety protocols including wearing their PPE kits before entering the premises, visually checking the markers, motors, and voltage meters related to smelting, and triggering emergency protocols as required. A comprehensive evaluation mode in the end tested their understanding.
Return on Investment :
Our client witnessed a remarkable return on investment on the VR training simulator in the form of:
- 30% time reduction in onboarding, training, and certifying the new recruits remotely on the safety processes
- 30% improvement in Information retention and a reduction in refresher training
- 50% reduction in the dependency on the actual manufacturing machine for training purposes
- Improved throughput and amp
- 40% reduction in tickets related to safety issues
