Introduction
Training employees to consistently follow critical procedures while following safety protocol is one of the most important and most difficult tasks, especially in high-risk industries.
You might be reading this from a LOTO technician perspective and think about all the different lockout tagout procedures you’ve seen go wrong, or you may be thinking from a chemical processing point of view and remembering the times chemical hazard that could have easily been avoided by not doing process steps incorrectly or being complacent.
Whatever the case, complex processes in high-risk industries need to be performed correctly at all costs, and this relies on a lot of repetition, and building muscle memory.
Traditional approaches to training like classroom lectures with powerpoints, instructional manuals and checkboxes often fall short. The best option behind actual hands-on training is video-based training, but while classroom sessions and passive videos can explain a procedure, they don’t build muscle memory.
Virtual Reality (VR) training closes that gap by placing users in realistic, interactive environments where they can perform tasks repeatedly, and helps to develop the physical memory and confidence required for safe, compliant work.
Why Repetition Matters in High-Risk Environments
In complex physical roles, it is not enough to know the steps. Workers need to be able to perform them automatically under pressure. This is especially true for safety-critical procedures like:
- Lockout Tagout (LOTO)
- Equipment shutdown or start-up
- Inspections and pre-use checks
- Tool changeovers
- Confined space entry protocols
Repetition is key to mastering physical skills, and VR excels in providing unlimited, risk-free practice. In manufacturing or logistics, employees can practice complex or repetitive motions until they achieve proficiency, with each training session reducing errors and increasing physical memory.
Repetition turns knowledge into instinct. The more often a procedure is physically performed in training, the more likely it is to be done correctly in the field.
How VR Builds Muscle Memory and Procedural Accuracy
VR training gives employees a risk-free space to physically rehearse complex sequences. Unlike video or written instruction, VR places the learner inside the task, using head and hand tracking to guide movement, simulate errors, and reinforce correct technique.
- Learners perform each action step-by-step using their hands (or controllers if not using hand-tracking)
- Systems give immediate feedback on correct or incorrect decisions
- Modules can be repeated until performance is accurate and consistent without extra cost, other than time spent.
VR training doesn’t just stop at muscle memory, but imprints the steps into a user’s mind to build procedural fluency: the ability to carry out critical tasks smoothly even under stress.
Applying SOPs in Realistic Scenarios for Better Compliance and Recall
Standard Operating Procedures (SOP) are essential, but memorizing steps on paper is almost never going to be enough. VR lets learners apply SOPs within realistic, interactive scenarios that mimic actual working conditions. This hands-on simulation-based approach helps users understand why each step matters, rather than just what the steps are, and is much better at enhancing memory recall of the correct steps for the process.
By practicing SOPs in a virtual environment, employees build muscle memory and situational awareness. They experience the consequences of skipping or incorrectly performing steps safely, which improves retention and compliance. This practical application reduces errors and increases confidence on the job.
Case Studies & Examples of VR Training Projects That Build Muscle Memory for Complex Processes
1. Lockout Tagout VR Training: Our clients Kinross Gold Corporation, one of the top gold-mining companies worldwide, and Daikin Global, the world’s largest air conditioner manufacturer had two unique versions of our lockout tagout interactive VR training program, designed specifically on their facilities and equipment. The lockout tagout training followed an in-depth instructed VR simulation of the complex 8-step procedure with the main steps for lockout tagout as well as PPE with detailed instructions for standard operating procedure (SOP).
Every step can be repeated endlessly until mastered. Theoretically, the scenarios in our training application can be expanded on to range from simple single-source isolation to more complex systems with hidden risks, or scenarios needing multiple users, or unique steps. This repetition, combined with real-time feedback, builds both competence and confidence.
2. Ammonia Transfer VR Training: We developed a comprehensive VR training program for Nutrien Ag Solutions, focusing on the safe transfer of ammonia, a highly hazardous chemical requiring over 60 precise steps including all the steps for the site setup, all the steps for connecting and disconnecting the equipment in the correct order and locations with detailed safety instructions. The ammonia transfer VR simulation replicates Nutrien’s real site, allowing users to interact with equipment, valves, and controls as they would in reality.
The training includes three modes: Training Mode (guided steps), Practice Mode (attempt without steps, but requesting hints as an option if users are stuck), and Assessment Mode (performance tracking). This approach ensures that users can practice and master the procedure without exposure to actual hazards.
3. HGV Pre-trip Inspections and Driver Training: For Schneider National, we developed a VR training course to train for all the steps a driver should take in order to complete a safe left-turn at an intersection, covering Schneider’s Five S’s: Set Up, Signal, Slow Down, Survey, and Steer. The left-turn was one module, but a second module included a brief walk-through covering what needs to be checked in a pre-trip inspection.
Theoretically HGV inspections could use VR training for any particular compliance standard such as Class A CDL Pre-Trips in the US, Standard UK HGV Daily Walkaround Checks, Australian Heavy Vehicle Inspection Guidelines, etc. It can also incorporate checks specific to industries, like DOT compliance for hazardous materials transport or ELD-mandated inspections for fleet operations.
This driver training offers a much stronger way of teaching and practicing new or experienced drivers. It can be used to transition experienced drivers out of any bad habits they may have on the road in real life, and condition them to instinctively follow compliance and company guidelines.
4. Complex equipment assembly for TMQ53: SHIIFT created a VR training program for assembling and operating the TMQ-53 Tactical Meteorological Observation System. The highly expensive equipment includes over 80 physical components, and there are a limited amount of TMQ-53 owned by USAF.
On top of this, United States Air Force Airmen are required to take refresher training and have practice assembling the equipment. This proved to be a massive logistical challenge with significant costs for USAF, which is where our VR training comes in to guide users through setup and the entire process of assembling the equipment from it’s parts.
This immersive training reduces the need for physical equipment and minimizes travel costs, which had a massive impact straight away for the air force, cutting down their spending by $2,500,000 in just the first 6 months of using the product.
A fun anecdote from when we physically delivered and demonstrated the project was how amazed and shocked that one of our developers who had tested the training process so many times using the VR training was able to do the same process on the real equipment faster or as fast than the airmen who’ve actually assembled the real thing before.
5. Confined space training: We developed a brief confined space training simulation experience in VR for the Ministry of Defence, giving them the opportunity to mission rehearse and practice the correct process for operating in confined spaces, specifically escaping a submarine.
6. Surgical process training: SHIIFT Training developed a demo for Baylor College of Medicine showcasing how virtual reality can be used to practice surgeries with no risk, unlocking powerful possibilities like endless practice without the use of expensive cadavers.
7.Utilities Companies Procedure Training: We also worked with Thames Water, the UK’s largest water and wastewater company that covers takes care of water for 16 million people. We created a virtual reality training, that doesn’t use VR headsets but uses a dome room covered in screens on every inch of the wall to let utilities employees practice and learn procedures.
Deployed at Lanes Group Learning Centre in Slough, the training was a big hit for their on-boarding experience, resulting in £1m reduction in physical training costs, 9% increase in trainee happiness, and a 57% reduction in employee attrition.