Client's Testimonial

"The VR training from Developers.dev has transformed our onboarding process. New hires now step onto the factory floor with confidence and a deep understanding of the assembly sequence. We've seen a 70% reduction in initial assembly errors and a significant drop in minor safety incidents. The ROI was clear within the first six months."

John Miller, Director of Operations, Titan Machinery

Client Overview

Our client is "Titan Machinery," a global leader in heavy equipment manufacturing, faced significant challenges with training new assembly line workers. Their equipment is complex and potentially dangerous, and on-the-job training led to production slowdowns and occasional safety incidents. They needed a standardized, safe, and repeatable way to train employees on multi-step assembly processes.

Problem

Titan Machinery needed to reduce the time and risk associated with training new assembly line workers, improve knowledge retention, and standardize its training process across multiple global facilities.

Key Challenges

Safety:

The primary goal was to allow trainees to learn in a zero-risk environment.

Complexity:

The assembly processes involved dozens of steps and multiple tools, which needed to be simulated accurately.

Standardization:

The training needed to be identical across different plants in the US and EMEA.

Integration:

The training results needed to be logged in their existing Learning Management System (LMS).

Our Solution

Developers.dev deployed a "DevOps & Cloud-Operations Pod" to create an immersive and interactive VR training simulation for Titan's main engine assembly line. The solution was built in Unreal Engine for high-fidelity graphics.

🏭 Realistic Virtual Factory:

We created a 1:1 digital twin of the relevant section of their assembly line, including all tools, parts, and machinery.

👆 Interactive, Step-by-Step Guidance:

The simulation guides the user through the entire assembly process with visual cues, audio instructions, and interactive elements.

❌ Error Detection and Feedback:

The system detects when a user makes a mistake (e.g., uses the wrong tool or part) and provides immediate corrective feedback.

🔗 LMS Integration:

We developed a custom API to connect the VR application to their corporate LMS, automatically updating training records upon successful completion of the modules.

Implementation and Execution

Discovery & Architecture:

Our team visited the client's facility to capture detailed photographic and video references of the assembly line.

Infrastructure as Code:

We converted the client's engineering CAD files for the machinery and parts into performance-optimized 3D models for Unreal Engine.

Agile Development:

We worked closely with their veteran trainers to script the step-by-step procedures and define common errors.

CI/CD Pipeline:

The project was managed in agile sprints, allowing the client to review and provide feedback on the simulation at every stage.

Performance Testing:

We integrated a networking layer to allow for a "trainer mode," where an instructor could join the virtual session to observe and guide the trainee.

Phased Rollout:

The application was deployed to PC-tethered VR headsets located in dedicated training rooms at each of their manufacturing plants.

Positive Outcome

📉 70% Reduction in New Hire Errors:

Trainees who completed the VR simulation made significantly fewer mistakes during their first week on the actual assembly line.

🛡️ 90% Reduction in Training-Related Accidents:

Safety incidents during the training period were virtually eliminated.

⏱️ 25% Faster Onboarding:

The time required to get a new employee fully productive on the assembly line was reduced by a week.

🌍 Standardized Global Training:

Every new employee, whether in the US or Germany, now receives the exact same high-quality training.

Why Choose Us

⚙️ CAD to VR Pipeline:

We demonstrated expertise in handling and optimizing complex industrial CAD data.

🎨 High-Fidelity Graphics:

Our use of Unreal Engine delivered the photorealism the client required.

🤝 Enterprise Integration:

We successfully integrated the VR app with their existing corporate LMS.

👥 Collaborative Approach:

We worked as a partner with their subject matter experts to ensure accuracy.

🏆 Focus on Business Outcomes:

The project was driven by the clear goals of improving safety and efficiency.

📈 Scalable Solution:

The architecture was designed to easily add new training modules for other assembly lines.

🔒 Secure & Reliable:

Our mature development process ensured a stable and bug-free final application.

🌐 Global Delivery:

We were able to support their teams in both the USA and EMEA.

🔑 Turnkey Solution:

We managed the entire project lifecycle, allowing the client to focus on their core operations.

Conclusion

Through a strategic partnership with Developers.dev, Titan Machinery successfully implemented a state-of-the-art VR training program that enhanced worker safety, improved operational efficiency, and delivered a significant and measurable return on investment.

Enhancing Worker Safety and Efficiency with a VR Assembly Line Training Module

Industry Manufacturing