Project Completed

From Subjective to
Standardized.

See how Real Talent Engineering (TVS Group) replaced manual "muscle memory" training with Digital Twins to achieve Total Productive Maintenance (TPM) goals.

100%
PPE Compliance
0
Training Injuries
Standard
Defect Detection
Experience Snapshot Interact in 3D
G
GRAHAs VR

Transforming Manufacturing @ Real Talent Engineering 🏭 #VR #TPM

The Digital Twin

Experience the Fidelity

This is the level of detail trainees see inside the headset. Interact with the model below—rotate, zoom, and verify the defects yourself.

Drag to Rotate • Pinch to Zoom

The Challenge: The Cost of Subjectivity

In high-precision manufacturing, Deburring is an art form. It relies heavily on muscle memory. One operator might consider a surface "smooth enough," while another spots a microscopic burr. This variance leads to inconsistent quality output for Real Talent Engineering.

High-Risk Training

The deburring process involves high-velocity particles. Training new hires on the shop floor carries inherent safety risks regarding eye injuries.

The VR Solution

We deployed a physics-based Digital Twin on the Meta Quest 3S, creating a "Golden Standard" for defect detection and enforcing PPE.

Key Results for TPM Goals

  • Zero-Risk Onboarding New hires make their mistakes in the metaverse, not on the production line, saving raw material costs.
  • Data-Driven Proficiency Management now has empirical data on trainee performance (accuracy, speed, safety compliance) before they touch a physical part.

Frequently Asked Questions

Common questions about VR implementation for Industrial Quality Control.

How does this solution support TPM goals?

Total Productive Maintenance (TPM) aims for Zero Accidents, Zero Defects, and Zero Breakdowns. Our VR solution directly supports this by:
1. Zero Accidents: Mandating virtual PPE compliance (Safety Glasses/Gloves) before the simulation starts.
2. Zero Defects: Standardizing the inspection process so every operator identifies defects (like Blow Holes) identically.
3. Autonomous Maintenance: Building correct tool-handling habits to prevent equipment misuse and wear.

How does VR training standardize the deburring process?

Deburring often relies on "muscle memory," leading to inconsistent results. Our VR solution creates a "Digital Twin" of the workstation, allowing operators to practice standard operating procedures (SOPs) and tool handling in a controlled environment. This ensures every technician trains on the exact same process—specifically focusing on critical zones like the Inlet Side and V-Band Outlet—eliminating subjectivity.

Can VR really replace physical inspection training?

It enhances it. Traditional training often lacks a variety of "defect samples" because you can't always find a rusted or damaged part when you need one. In VR, we can instantly simulate critical defects like blow holes, line marks, rust, and thread damage. This trains the operator's eye to spot specific issues that might only occur rarely in production, ensuring they are ready for any scenario.

What safety risks does this eliminate?

The deburring process involves high-velocity particles and compressed air. In our VR module, safety compliance is mandatory; users must virtually equip safety glasses and gloves before the system allows them to work. This builds a "safety-first" habit without the risk of real-world injury during the learning phase.

What hardware is required to run this training?

This solution was deployed using the Meta Quest 3S. It utilizes the OpenXR platform to deliver high-fidelity tracking and realistic visuals, ensuring the virtual experience mirrors the physical shop floor.

Client Feedback

Translated Summary "The biggest challenge in deburring is safety, especially with compressed air and flying particles. This VR training creates a habit of wearing safety glasses and following protocols before the operator even enters the shop floor. It effectively prevents eye injuries and ensures compliance."
Mr. R. Saravanan
Mr. R. Saravanan
Quality Assurance
Real Talent Engineering