Industry:

Auto & Manufacturing

VR Simulation Training for Welding Operations in Automotive Manufacturing

Training technicians across multiple plants on complex welding machinery in lifelike yet fully immersive virtual environments. Our VR training solution enables faster competency, reduces errors, and supports the increasingly digital demands of blue-collar jobs, making it essential for future-ready workforce upskilling.
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Auto & Manufacturing

Why Traditional Trainings doesn't Cut it Anymore?

Traditional methods required live machine downtime, increased safety risks for new joiners, and lacked standardization. With multiple types of welding technologies in use from MIG welding to robotic welding stations, it is challenging to:

  • Train new recruits without interrupting production
  • Standardize training across locations
  • Reduce early-stage human error and safety incidents
  • Upskill workers quickly without physical access to machines

The need was clear: create a safe, realistic, and repeatable training environment accessible on demand.

Automotive Manufacturing Training in Virtual Reality (VR)

VR offers hands-on, and immersive learning, allowing workers to simulate real-world scenarios without risk. It enhances skill retention, provides location-independent access, and boosts digital confidence. Furthermore, companies using immersive training report up to 40% faster onboarding and 30% fewer job errors. This enables faster competency, reduces errors, and supports the increasingly digital demands of blue-collar jobs, making it essential for future-ready workforce upskilling.

Key takeaways

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Upskilling Blue Collar Workers through Virtual Reality

We designed and deployed a multi-module VR simulation system, compatible with wireless VR headsets (Meta Quest 3), enabling factory workers to experience lifelike welding training in a fully immersive virtual setup. A Virtual Reality (VR) Simulation-Based Training solution tailored for welding operations, eliminating risks while improving onboarding and retention across manufacturing units.

Modules Developed

  1. MIG Welding Machine
  2. Stud Welding Machine
  3. Manual Projection Welding Machine
  4. Manual Spot Welding Machine
  5. Robotic Welding Machine
  6. Stamping Operations

Each machine simulation offered:

  • 5-minute guided training with interactive controls
  • Multilingual audio narration (Tamil, Telugu, etc.)
  • Built-in safety compliance training
  • Assessment quizzes for performance evaluation
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The VR experience began with a Mixed Reality-based company introduction, delivered by a digital avatar inside a DOJO-style virtual room. We developed five detailed modules, each focused on a specific welding machine—MIG welding, stud welding, manual projection welding, manual spot welding, and robotic welding. 

Each module offered a short hands-on simulation where the trainee interacted with the machine in a lifelike virtual setup. Users received real-time guidance through AI-generated multilingual voiceovers and took a short assessment at the end of each session.

We custom-built 3D models of each machine using CAD files, photographs, and workshop layouts, ensuring every visual matched what the trainee would encounter on the factory floor. We avoided generic assets and created everything from scratch, including the spatial design of ladders, harnesses, and safety fixtures.

The entire training ran seamlessly on Meta Quest 3, offering wireless, mobile, and scalable deployment across plant sites. Dashboards allowed training heads to monitor progress, safety compliance, and performance, bringing real-time visibility to workforce efforts.

Results & Impact

While specific metrics remain confidential, the deployed VR training modules have:

  • Reduced operator errors during onboarding
  • Eliminated machine downtime for training
  • Improved retention and confidence
  • Delivered consistent, standardized training across multiple plant sites

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Visual Experience

Each training session offers a first-person view inside the workshop, where trainees:

  • Interact with machines virtually
  • Perform welding operations step by step
  • Receive voice-guided instructions 
  • Take an end-of-session assessment quiz with real-time feedback

Looking to Train Your Factory Workforce Using VR?

We specialize in creating custom VR training modules for manufacturers, especially those in automotive, electrical, and industrial sectors. From stamping operations to transformer testing, if your team uses a machine, we can train them in it, virtually. Schedule a Demo to explore how immersive training can revolutionize your L&D.

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