LOTO Safety Simulation
We developed a Virtual Reality (VR) safety training simulation designed to teach workers proper Lockout/Tagout (LOTO) procedures in an industrial warehouse environment.
The experience replicates real-world workflows, ensuring workers understand how to safely shut down machinery before maintenance—reducing risk of injury and improving compliance.
Client Requirement
The client required a training solution that could:
- Simulate real warehouse working conditions
- Train workers on proper LOTO procedures
- Reduce workplace accidents caused by unsafe machinery handling
- Provide step-by-step guided training
- Ensure high engagement and retention through immersive learning
We created a fully interactive VR training experience where users go through the complete LOTO process in a realistic warehouse setting.
The simulation guides users through:
- Emergency awareness via announcement system
- Preparing for LOTO procedure
- Wearing safety gear
- Locking machinery using proper tools
- Safely completing maintenance tasks
Our Solution
Key Features
Realistic Warehouse Environment
- Active industrial setting with workers and machines
- Real-world layout and workflow simulation
- Immersive and practical training environment
- Announcement alerts workers to initiate LOTO procedure
- Workers move to a safe zone
- Clear instructions guide each step of the process
Guided Training Flow (Step-by-Step)
Safety Gear Interaction
- Equip safety jacket and protective gear
- Reinforces real-world safety protocols
- Interactive wearable system
- Apply multiple locks to machines
- Secure a main valve using a large lock
- Proper tagging and locking workflow
- Visual confirmation of machine shutdown
Lockout/Tagout Procedure Simulation
Machine Shutdown System
- Machines turn off after proper lock procedure
- Ensures correct sequence before maintenance
- Realistic cause-and-effect interaction
- Worker performs task after machine shutdown
- Reinforces importance of safe workflow
- Completion-based training experience
Maintenance Simulation
Technology Stack
- Unity 3D
- OpenXR / Meta XR SDK
- XR Interaction Toolkit
- Custom interaction & workflow system
- Optimized for Meta Quest devices
- Improved worker understanding of LOTO safety procedures
- Reduced training risks by simulating dangerous scenarios
- Increased engagement compared to traditional safety training
- Delivered a scalable training system for industrial use
Results
Challenges & Solutions
Challenge: Representing complex safety procedures clearly
Solution: Designed a step-by-step guided workflow with visual and audio cues
Challenge: Ensuring realistic interaction with equipment
Solution: Built custom interaction systems for locking, tagging, and tool usage
Challenge: Maintaining performance in a detailed environment
Solution: Optimized assets, lighting, and interaction systems for VR
