Background
Real Talent Engineering (RTE), a manufacturing division within the TVS Group, faced three compounding challenges in its shopfloor training programme. Hands-on training with grinding wheels and deburring tools carried significant injury risk for new recruits. Senior operators were being pulled off the production line to train juniors, eroding Overall Equipment Effectiveness (OEE). And the lack of standardised visualisation was creating inconsistency in inspection quality and driving up scrap rates.
To address these issues, RTE partnered with GRAHAs VR (Square Comp Solutions), a Chennai-based specialist in industrial VR training, to build a virtual reality training simulation for its deburring and grinding operations.
The Deployment
GRAHAs VR developed a real-time 3D digital twin of the shopfloor environment, including the grinding and deburring equipment used in daily operations. Trainees engage with the simulation via VR headset before setting foot on the production floor, practising safety protocols, tool handling, and Standard Operating Procedure (SOP) adherence in a zero-risk virtual environment. The solution is compatible with standalone and PC-tethered headsets and can also be delivered via WebAR on mobile devices for wider accessibility.
The VR content was designed to replicate the full procedural context of deburring work, with particular emphasis on compressed-air hazards and eye protection compliance, identified as the most critical safety risks in the pre-VR training model.
TPM Audit
The deployment was independently audited by JPIM Associates, international Japanese TPM (Total Productive Maintenance) auditors, in January 2026. The auditors cited the VR solution as a key enabler of two core TPM pillars: Autonomous Maintenance and Skills Development. The audit resulted in a high-confidence rating across all assessed dimensions.
Outcomes
- Training time reduced by 40% compared to the previous instructor-led shopfloor method
- Zero safety incidents recorded during or following the VR training rollout
- 100% SOP adherence achieved across trained operators
- High auditor confidence confirmed by JPIM Associates
Mr. Saravanan, Quality Assurance Head at Real Talent Engineering, noted that the VR simulation establishes safe habits before operators enter the shopfloor, preventing eye injuries and ensuring compliance with protective equipment protocols.
