A manufacturer rolled out a full simulated factory floor for new operator training across two facilities.
saved per operator onboarding
Average live-floor shadowing time dropped from 9 hours to under 3 hours per operator after simulation pre-qualification was introduced.
protocol consistency across facilities
Both facilities now run identical onboarding assessment criteria, measured by training audit scores — previously diverged by 34 percentage points.
training throughput increase
The simulation runs without pulling experienced staff, enabling the manufacturer to onboard groups concurrently. Monthly throughput grew from 6 to 29 operators.
The challenge
Onboarding new operators required pulling experienced staff off the line for shadowing sessions that averaged 9 hours per new hire. The two facilities ran different onboarding protocols, leading to inconsistent safety behaviour and a skills gap that only became visible after workers were deployed independently. Training throughput was the limiting factor on headcount growth.
The solution
MosaicXR built a simulated factory floor in Unity that replicates both facilities — machine layouts, control panels, and emergency procedures — with scored training scenarios for each operational role. Trainees complete the simulation independently before any live-floor time. The system logs performance data and flags individuals who need additional coaching before they operate machinery.
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