Advantages of VR in steel production training:
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Enhanced security: Provide a safe learning platform even for high-risk scenarios and rare automation failures
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Cost-effectiveness: One-time investment produces long-term benefits and significantly reduces training costs
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Time Efficiency: Operators can start hands-on training from day one, eliminating the need for ongoing instruction and saving countless training hours
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Rapid Assessment: Speed up the process of assessing a potential operator’s suitability for the job
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Attract new employees: Using cutting-edge technology in training can be a huge draw for potential employees
Addressing the high-risk situation in steel production
Steel production is inherently associated with a variety of high-risk operations and scenarios. The production process involves melting metal at extremely high temperatures and can be dangerous because workers are often exposed to extreme heat, molten metal, and heavy containers and machinery. Any mistakes or spills during this operation can have catastrophic effects.
As safety is an important issue in the industry, Tata Steel has been leading the way in automating many aspects of steel plant operations. However, as is the case with machinery, malfunctions may occur requiring manual override of the automated system. Given the often reliable nature of automation, this poses significant challenges as operators are often inexperienced with manual procedures.
Due to the complexity and inherent risks of the production process, crane operators must receive comprehensive training that equips them with practical experience to respond quickly to any situation they may encounter. In order to move away from the traditional and time-consuming apprenticeship-style way of training new drivers, the transition to a virtual environment was the next logical step for Tata Steel’s IJmuiden plant. When accessing funding for digital transformation faced challenges, steel mills took the problem into their own hands, and it turned out the solution was closer than they thought.
Partnership to improve crane operator training efficiency and safety
Fortunately, Tata Steel's IJmuiden plant spotted the potential in local solution provider Steel Sim VR, which is located just 10 kilometers from their site. With a strong track record of successfully building crane simulators for Tata Steel in Port Talbot, UK, and ArcelorMittal in Ghent and Bremen, Steel Sim VR is leading the shift to virtual training ideal partner. Taking advantage of this opportunity, Tata Steel's IJmuiden plant partnered with Steel Sim VR to create an innovative digital model of its loading crane.
Founded in 2018, Steel Sim VR was born out of a one-off project to develop a lean and efficient VR-based training tool for the steel industry. The company aims to revolutionize crane operator training by replacing dangerous, expensive and time-consuming traditional training methods with safer and more streamlined virtual simulations. “We are one of the first companies to integrate virtual reality into this type of simulation training,” explains Jan Luc Zandjans, co-founder of Steel Sim VR.
Varjo's superior clarity and comfort allow users to train comfortably for long periods of time, making it the perfect choice as the cornerstone of their training solutions. "After testing the Varjo we found it to be the best option available, so choosing a state-of-the-art headset for trainers was an easy decision. We were surprised as we had never seen anything else quite like it, "Zanjans said.
“The virtual reality simulation is an exact replica of what happens in real life. The simulation feels like operating a real crane.
The collaboration between Tata Steel and Steel Sim VR paves the way for a state-of-the-art VR-based simulator designed to simulate training in realistic crane cabins. With the Varjo Aero headset, everything inside the virtual cabin is clearly visible, including details such as various mission screens, text and numeric displays, cabin buttons and joysticks. "With Varjo, we were able to create a lifelike cabin for our training simulator, which really enhanced the overall training experience," said Zandjans.
Once the VR simulator is fully operational at Tata Steel's IJmuiden plant, the training program will be divided into two categories: one for new employees and the other for experienced operators. Novice operators will receive basic training, experienced operators will receive refresher courses, and both groups will be trained to handle special emergencies, such as automation failures or breaches. The simulation accurately mimics actual crane movements, helping operators gain valuable muscle memory when such events occur.
“The virtual reality simulation is an exact replica of what happens in real life. Once you turn on the headset, you feel like you are actually inside the steel plant,” said Hans Pronk, steelmaking operations expert at Tata Steel Europe. “Feedback from our crane operators, especially those with extensive experience, has been very positive.”
Another core feature of the solution is its innovative data dashboard that tracks metrics for learner performance. The tool breaks down scenarios into specific tasks and objectives while recording the student's "flight path" to provide insightful feedback on their movements. Using a variety of data points, operators can integrate this data with reporting systems to analyze trends and identify problem areas. For example, a data dashboard can answer queries such as "Which situation causes the most conflicts?"
“The safety provided by high-quality simulator training is unmatched.”
Unparalleled training capabilities
The benefits of VR solutions are many. First, simulators provide an environment to practice disaster scenarios, a training module previously lacking across the industry. With simulators, operators can practice situations that they would not be able to safely handle in real life.
Additionally, simulator training is several times more cost-effective and efficient than traditional methods. It allows operators to train independently from day one, saving time and money compared to traditional crane training, which requires a mentor or experienced crane driver to work with a less experienced crane operator. The crane driver was present together. "After a few hours of training on the simulator, the operators are ready to work on a real crane together with their colleagues. Therefore, we expect that the system will significantly reduce training time." Hans, expert at Tata Steel Pronk said.
One of the benefits of this technology is its flexibility. The initial investment is one-time, but the benefits continue year after year. "You can easily switch to another application or environment without making any major investment in hardware; the only investment required is software," Pronk explains.
Pushing the industry into the future
Tata Steel's foray into virtual reality signals the company's readiness to embrace future innovations, proving that the steel industry is no longer new to digital transformation. Latest technological advancements have developed immersive solutions into a new cost-effective model, paving the way for their widespread adoption across the industry. “We now have all the necessary hardware and software to build a high-quality simulator at a competitive price,” Zandjans said. “This development makes it easier for our customers to choose between traditional and simulator training.”
Steel Sim VR sees great promise for immersive training solutions in the steel industry, similar to the widespread adoption in aviation. “There is no doubt that training simulators will become the new standard for training personnel, especially in tasks involving heavy machinery and hazardous environments,” says Zandjans. “I predict that within the next five years, simulators will become the industry standard training method.”