Relevant case studies

Blog post: 10/10/2025 9:40 am

Author: Spark Team

VR SOP Training for Steel Mills: Melt Shop, Casting & Rolling

Custom VR to reduce high-energy risk and stabilise complex production sequences

Integrated and mini-mills juggle molten metal, high-energy equipment and tight production windows. Spark designs and builds bespoke VR SOP training that mirrors your EAF/BOF, ladle metallurgy, continuous casting, reheating furnaces and rolling stands—so operators can practise critical steps without exposure to heat, motion and pinch hazards.

Steelmaking pain points our VR solves

• High-energy hazards: EAF operations, tap-to-tap discipline, furnace interlocks and LOTO.
• Continuous casting: tundish prep, level control, breakout prevention, strand changes.
• Rolling lines: threading, cobbles, changeovers, speed/temperature coordination.
• Maintenance: refractory checks, roll changes, bearing lubrication, alignment.
• Quality & yield: inclusion control, surface defects, trim optimisation.

Our bespoke build method

1. SOP capture & hazard mapping: interlocks, alarm sets, line layouts and emergency plans.
2. Scenario design: EAF start-up, caster start/stop, cobble response, roll change procedures.
3. AI avatar coaching: enforces hold points, temperature windows and inspection routines.
4. Assessment: right-first-time metrics, time-to-safe-state, critical control adherence.
5. Integration: LMS links, multilingual packs, role-based modules (ops, maintenance, QA).

Operational outcomes

• Reduced incidents in melt shop, caster and rolling mill.
• Fewer cobbles and improved line stability.
• Higher yield through standardised execution and faster recovery.
• Audit-ready competence evidence for customers and regulators.

Why Spark

Your VR twin reflects your plant, not a template—accelerating safe learning for high-energy, high-throughput operations.

Scope a bespoke steelmaking VR SOP programme. Contact Spark.

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