Critical Training in a Factory that Never Sleeps. 

The Challenge

The production site operates continuously, with rotating shifts and no in-house trainers available to run extended training sessions. Stopping production was not an option, yet all teams needed to be trained on high-risk procedures: LOTOTO and spill response. Plus, we got tasked to run both trainings in one single day.

How do you train everyone, properly, in the shortest possible time, without stopping production?

The Solution

Graham Packaging partnered with Altheria to deploy a Safety Day directly on site.

Instead of asking teams to adapt to training, Altheria adapted the training to the reality of the factory floor. The solution was simple:

• Multiple VR training stations deployed on site
• Altheria staff handling the full setup, coordination, and facilitation
• A carefully chosen time window in late afternoon and evening, right between shifts
• 2 Sessions per employee, with shifts optimised minute by minute

Using VR, operators were placed in realistic environments, allowing them to actively practice LOTOTO and spill response procedures.

The sessions are highly interactive, which means that trainees move around, use their hands and bodies to go through the training. We don't go for passive 360° VR, otherwise we would miss:

• Engagement through interactive scenarios
• Immersion through realistic industrial environments
• Active pedagogy by learning through action and repetition

The Results

40 employees were trained in only 4 hours, proving that effective safety training is possible even in the most constrained industrial environments.

Operators left the sessions with strong muscle-memory and understanding of the two procedures and an improved confidence in these stressful situations.