PLANT-SIM
Heavy-process plant safety & operator training.
PLANT-SIM trains operators, riggers and safety officers across India's cement, steel, foundry and heavy-engineering plants — blast-furnace lancing, ladle metallurgy, kiln entry, EOT crane operations, electrical LOTO and plant-floor robotic-cell onboarding. Built for Tier-2 multi-plant operators that need control-systems-grade fidelity (DCS, PLC, conveyor logic) at a price point that scales across distributed plants. Multilingual instruction in Hindi, Bengali, Telugu, Marathi and English — the languages an Indian heavy-manufacturing workforce actually trains in.
Every feature, audit-grade.
- F / 01
Blast-furnace lancing & EAF hot-metal handling
Lancing, ladle handling and hot-metal flow rehearsed at the actual sequence speed. Built against operator-fatality root-cause data from Indian integrated steel plants — the moments where 'shadow the senior' is unsafe and ineffective.
- F / 02
Cement kiln entry, hot-work & dust-explosion drills
Kiln burner-zone entry, refractory inspection, hot-work permit discipline and dust-explosion response. Cement plants run continuous — shutting a kiln to train is not a real option, and PLANT-SIM is the answer.
- F / 03
EOT crane & operator skill — IS 7969 aligned
Overhead-crane operations modelled to IS 7969 cab fidelity, with load-chart compliance, blind-spot drills and tandem-lift coordination. Less premium than a Varjo motion-platform sim, an order of magnitude cheaper, and closer to the operator's daily reality.
- F / 04
Forklift, reach-truck & robotic-cell onboarding
Warehouse and shop-floor mobile-equipment training — forklift OSHA-aligned, reach-truck per DGFASLI, plus robotic-cell barriers and pinch-point drills for auto-component manufacturing. Built for the workforce that turns over fastest and gets injured most.
- F / 05
Electrical safety, LOTO & arc-flash for plant electricals
Sub-station LOTO, MCC discipline, motor isolation and arc-flash PPE selection — every plant runs the same hazards, and PLANT-SIM standardises the response across multi-plant footprints.
- F / 06
DCS / PLC familiarisation & shop-floor SOP walkthroughs
Control-systems-aware modules — DCS console familiarisation, PLC-driven interlock recovery, conveyor sequence start-up. The control-room layer that pure-software competitors typically skip and where mechatronics expertise matters.
From briefing
to debrief.
- 01ToolboxPre-shift toolbox talk, JSA, PPE check and isolation plan.
- 02SetupEquipment walk-around, gas tests, energy isolation, area cordon.
- 03ExecuteThe lancing, the lift, the start-up sequence — at operating cadence, not demo cadence.
- 04Hold-pointsEngineered stops where a competent person verifies before work proceeds.
- 05DebriefSupervisor-graded review with NSC-aligned near-miss capture and audit log.
Other simulators.
Bring the simulator
to your operation.
On-site evaluation for plant managers, safety directors, training schools and skill missions. We deploy the kit to your location — standalone headsets, full standards-aligned curriculum, instructor brief included.