VR Hazard Recognition Training System
Immersive VR system designed to strengthen warehouse safety culture by improving hazard recognition, PPE compliance, and real-world incident prevention.Client & Project Overview
A global industrial operator managing multiple warehouse facilities approached SiriusOne to elevate safety performance and reduce recurring incidents. Traditional classroom training and Hazard Hunts lacked consistency, realism, and measurable outcomes. SiriusOne designed a VR-based hazard recognition training system that standardizes OSHA-aligned safety procedures, improves employee situational awareness, and delivers validated performance analytics across all warehouse locations.
Business Problem
Warehouse teams frequently overlook risks due to routine familiarity and low engagement in traditional training formats. Paper-based materials fail to recreate real hazards, and trainers cannot reliably measure how well employees can identify risks under pressure. The organization needed a scalable, measurable, and highly engaging solution to address:
- Inconsistent hazard identification across shifts
- Repeated PPE violations
- Lack of standardized training across locations
- Inability to safely simulate chemical hazards
- Low retention and engagement in classroom modules
“SiriusOne transformed our safety training into a fully measurable, repeatable, and highly engaging process. Our teams finally see hazards before they happen.”
Senior HSE Manager, Global Operations
Tech Stack
Game Engine: Unity
Hardware: Meta Quest 3, Pico 4
Cloud: AWS S3, AWS Lambda, Analytics Pipeline
LMS: SCORM-compatible
Tools: Hazard randomization engine, SDS database integration
Languages: EN, AR, FR, DE, ES
Frameworks: OSHA-aligned hazard classification
#VRSafety
#WarehouseTraining
#XRLearning
Project Timeline
We followed a structured roadmap ensuring safety experts, XR engineers, and warehouse teams guided development from start to finish.
Duration
10 weeks
Effort
~3100 hours
Discovery & Research
2 weeks
Workplace assessment, Hazard Hunt analysis, OSHA mapping, training-flow design.
UX Design & Prototyping
2 weeks
Environment layout, hazard logic, PPE preparation room prototype.
Development
4 weeks
Two warehouse simulations (general & chemical), hazard randomization engine, multi-user mode, analytics integration.
Testing & Security Audit
1 week
Performance testing, hazard logic validation, OSHA alignment review.
Deployment & Training
1 week
On-site onboarding, instructor toolkit delivery, analytics dashboard setup.
Team involved
Delivery Manager
Coordinated execution and validated final training alignment.
XR Engineers
Developed interaction systems, hazard logic, and performance optimization.
3D Environment Artists
Created warehouse environments, assets, lighting, and equipment.
Safety Compliance Specialist
Ensured OSHA alignment, SDS accuracy, and correct hazard classification.
UI/UX Designer
Designed intuitive, accessible user interactions.
QA Engineer
Performed testing across Quest / Pico devices.
Solution Overview
SiriusOne built a fully immersive VR training system that teaches workers to recognize hazards, use PPE correctly, and respond to unsafe situations through realistic simulations.
PPE Preparation Room
A guided flow where trainees inspect, select, and equip PPE. Incorrect PPE blocks entry and prompts correction.
General Warehouse Simulation
Realistic hazards including: fall risks, forklift blind zones, unstable racks, blocked exits, electrical risks, manual lifting issues.
Chemical Warehouse Simulation
Includes chemical compatibility issues, spill scenarios, improper ventilation, SDS procedures, and PPE misuse.
Randomized Hazard Engine
Each session generates unique hazard sets — preventing memorization and building true hazard recognition skills.
Multi-User Mode
Up to 10 trainees plus instructor can train in the same virtual warehouse.
Scoring & Analytics
OSHA-referenced scoring, color-coded feedback, dashboards for performance tracking, and LMS integration.
Results
63% Improvement in Hazard Recognition Accuracy
Employees detect risks faster and more consistently.
52% Increase in PPE Compliance
Preparation flow reinforces correct gear usage.
34% Reduction in Near-Miss Incidents
Stronger situational awareness across warehouse teams.
4× Higher Engagement Compared to E-Learning
VR eliminates distractions and improves learning retention.
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