CASE STUDY > WELSPUN
Project summary
Challenge: Making sure the right muscle memory kicks in
Most of Welspun’s coating plant operators have been on the job for 5 to 15 years.
These operators periodically switch between Welspun's 3 External Coating Plants (ECP). All 3 have identical SOPs, but different floor layouts, including equipment positions and hazard zones.
It took one week to transition from one plant to another.
Because the differences turn operators’ experience against themselves. Muscle memory triggers operators to stand in the wrong spots and reach for equipment that was never there. An action that is right in one plant becomes wrong in another.
As a result, during the first hour of every changeover shift, Welspun recorded a disproportionate number of mistakes.
The operators didn’t need to learn anything. They needed to reorient away from the previous plant and towards the current plant.
Solution: A 10 minute VR refresher before every plant changeover
During a 3-day site visit at Welspun’s Anjari plant, our team held design-thinking sessions with the safety head, plant head, production engineers, and floor workers.
Through the sessions, the team understood the best way to solve Welspun’s problem was through memory refresher modules in VR.
For developing the modules, AutoVRse followed a non-linear process, where the teams worked in parallel.
Here are some of the highlights:
The Learning and Experience Design (LxD) team edited the modules to a 10-minute experience that fits into a pre-shift toolbox talk.
AutoVRse’s developers custom-coded a branching narrative to let Welspun operators choose teleport locations from which the experience continued.
Our art team created a Goldilocks zone between graphics and performance, making sure rotating machinery and visual effects didn’t slow down the experience due to drops in framerates.
The QA team took direct lessons from the plant teams about their processes to get into the perspective of experienced operators.
Throughout the process, we kept Welspun’s Single Points of Contact (SPOC)—client personnel coordinating the project—in the loop using a remote testing channel.
Result: 4 VR modules that logged 120 sessions in under 3 days
In addition, the team also created a 4th PPE module that was common for all the refresher modules.
After creation, the modules’ User Acceptance Testing (UAT)—a final round of testing by the client—logged 120 VR sessions in just 2 and a half days.
Post the UAT, Welspun's SPOCs conducted demo sessions to onboard new users on their own. 1,400 employees registered from across Welspun's pipe divisions.
Future: Turning every workflow into 3 re-usable training assets
Welspun wants AutoVRse to develop 5 additional modules in the coming months of 2026.
Conversations are underway for the next phase targeting workflows across Welspun's pipe manufacturing, production, and logistics operations.
Per the conversations, AutoVRse will turn each workflow into 3 re-usable training assets:
Web-based primer: A short, web-accessible version of the training.
VR drill: VR experience where operators practice the task.
Assessment: A test that measures the operator's understanding and retention.
All 3 combine into a single, complete training unit that Welpun can deploy across shifts without disrupting ongoing production.