Operators completed every SOP step. Not one skipped.
A leading integrated steel manufacturer was tracking near-miss incidents at switchgear panels. Classroom training had been refreshed twice without changing the trend. Drona VR deployed an electrical safety module replicating the plant's exact SOP. In evaluation, operators completed every SOP step. Not a single step skipped.
Live panel work was the highest near-miss category. Classroom retraining had not moved the number.
Leading integrated steel manufacturer
Leading integrated steel manufacturer with multiple plants across Eastern and Central India. Several thousand frontline operators across coke ovens, blast furnaces, hot strip mills, and finishing lines.
The customer's near-miss log showed the same root causes at switchgear panels quarter after quarter — voltage verification skipped, PPE wrong category, lockout sequence shortcut. Two annual classroom refresher cycles had not changed the trend.
DGMS audit trends had also shifted. Auditors were asking for evidence operators could perform the SOP, not attendance records. The customer's training documentation was attendance-only.
Module deployed: Electrical Safety.
VB Group EHS engineers configured the Drona VR Electrical Safety module to replicate the customer's exact panel-work SOP — voltage verification, PPE category selection, lockout sequence, and the energised-equipment decision point.
The module deployed first at the customer's flagship plant — 120 electrical maintenance operators completed the first cycle within 4 weeks. Trainer cast view enabled the EHS team to evaluate every operator in real time, not via post-incident review.
Deployment timeline.
Numbers from 90 days post-deployment.
Operators completed every SOP step.
In evaluation, every operator who took the assessment completed every step. Voltage verification became automatic. The energised-equipment decision was answered correctly in 100% of evaluation runs.
Near-miss trend declined.
Quarterly near-miss count at switchgear declined ~35% in the first 90 days. The trend continued into the following quarter.
Faster certification cycle.
Operator certification moved from a quarterly classroom-only cycle to monthly headset-based, accelerating turnaround three-fold without operational disruption.
Audit format accepted.
DGMS auditors accepted the per-learner per-step evaluation report as competency evidence. The customer's prior attendance-only documentation gap was closed.
In evaluation, our operators completed every SOP step on the Drona electrical safety module. Not a single step skipped. That's a measurable shift from classroom training.
Three modules. One platform.
Three takeaways from this deployment.
Plant-specific SOP fidelity drove adoption.
Generic electrical safety content from prior VR vendors had been dismissed by operators as "a game". Mapping the customer's exact SOP reversed that.
Cast view changed evaluation cadence.
EHS team moved from quarterly reviews of incident logs to weekly review of trainer cast recordings. Faster feedback loop, faster competency.
DGMS audit prep moved earlier.
Documentation generation per training session compressed audit-prep cycle from months to days.
Train integrated steel for the work where mistakes are audit findings.
Book a 15-minute discovery call. We will walk you through the modules deployed in this case study, on a real headset, with your SOP language.