case study
The Steel Industry's Leap into Immersive Intelligence
Steel manufacturing operates at extreme temperature, pressure, and complexity — making safety, maintenance, and precision top priorities.VB Metaverse bridges physical and digital operations through a complete suite of immersive and digital twin technologies, helping steel manufacturers train smarter, monitor safer, and operate more sustainably.
The Drona VR module delivers a fully immersive simulation platform built for training workers in hazardous steel environments — from blast furnace operations and rolling mills to emergency evacuation and confined space rescue.
* Process simulations for furnace, crane, and casting operations
* Emergency response drills for CO leakage and fire incidents
* Reduced incident potential by up to 43% in clients adopting Drona VR for EHS onboarding.
* Developed custom plant-specific scenarios mirroring exact blast furnace and rolling line conditions.
* 60% reduction in training duration
* 70% improvement in knowledge retention
* Zero physical exposure to hazardous environments
The MetWin and Magic modules empower engineers to visualize, manipulate, and interact with real-time plant data over physical assets — improving maintenance precision, layout design, and safety compliance.
* Real-time digital SOPs projected on equipment
* Collaborative design reviews for new line installations
* Magic MR accurately records operational timing and worker motion, enabling precise time-and-motion studies for productivity improvement.
* Integrated IoT and 3D piping data for high-risk zones, boosting CO-leak containment strategies in metallurgical processes.
* 35% faster maintenance cycles.
* 50% fewer operational errors.
* Improved plant layout safety and process efficiency.
The MetWin and Magic MR modules enable engineers, technicians, and supervisors to seamlessly visualize real-time plant data over physical assets — enhancing maintenance precision, operational consistency, and layout decision-making.
* Digital SOPs and workflows projected directly on machinery for hands-free execution
* Collaborative MR design reviews for line upgrades, new equipment installation, and layout optimization
* Magic MR captures precise time-and-motion analytics, supporting productivity benchmarking and ergonomic optimization.
* Integrated IoT feeds, 3D piping models, and hazard maps for high-risk metallurgical zones — significantly improving CO-leak prediction, containment, and response strategies.
* 35% faster maintenance cycles with guided MR workflows
* Up to 50% reduction in operational errors via real-time visual validation
* Safer, smarter plant layouts driven by data-rich MR design simulations
Akira 360 allows EHS teams to virtually immerse themselves into hazardous environments through real-time 360° camera streams, providing complete visibility during emergencies or routine inspections — without physical exposure.
* CO and toxic gas leak visualization and response coordination
* Live emergency command-center immersion for fire or explosion events
* Integrated AI-based gas detection analytics and thermal camera feeds for instant visual alerts.
* Developed remote response protocols that improved emergency reaction time by up to 50%.
* Zero personnel exposure in hazardous areas
* Faster emergency response and decision-making
* Real-time situational awareness across safety teams
Digital twin updates with IoT and live status sync
* 20% faster project decisions
* Enhanced transparency and client satisfaction
* Implemented high-precision LiDAR scanning to convert legacy plants into fully functional VR twins for real-time inspection.
* Enabled multi-disciplinary teams (mechanical, EHS, electrical) to collaborate on digital twins, reducing process hazards by over 60%.
* Sub-centimeter accuracy in infrastructure representation
* Multi-fold improvement in process safety and CO detection
* Reduced rework and improved asset lifecycle visibility
Benefits
Why Global Brands Choose VB Metaverse
Our Values
VB Metaverse unifies Drona VR, MetWin, Magic, Akira 360 and 360Vista Edge to boost safety and efficiency.
Use Cases
The Connected Ecosystem for Smart Steel Plants
Sustainability and Process Safety Leadership
VB Metaverse aligns with Industry 4.0 and Sustainability 5.0 principles, transforming traditional steel plants into smart, green factories.
Through 4 mm-accuracy digital twins, immersive VR safety training, and real-time monitoring via Akira 360, VB Metaverse ensures zero-risk safety culture, optimized energy efficiency, and measurable CO-leak reduction.
Conclusion: The Immersive Transformation of Steel Manufacturing
With the combined power of Drona VR, MetWin, Magic, Akira 360, 360Vista Edge, and LiDAR precision digital twinning, VB Metaverse is pioneering a new era for the global steel industry.From virtual training and real-time hazard visualization to CO detection and predictive maintenance, VB Metaverse delivers measurable gains in safety, speed, and sustainability — making every steel plant future-ready and digitally intelligent.