Sealing Operation

Introduction

Performing Sealing operation on a car is one of the most difficult and complex operations in an automotive manufacturing plant. Different nozzles are used for applying the sealant at different parts of the chassis. A close coordination between the mind and hand movement is required for the successful application of Sealant. Thus, a very high level of skill is required to perform this operation.

Complexities Involved

Sealing process involved the application of sealant through different nozzles at different parts of the chassis. On selecting a wrong one, the whole operation failed and the job line stopped. This reduced the efficiency and output of the plant. There were more than six types of defects that occurred while performing the operation. Some of these included sealer gaps, lumps and sealer Traces. A very precise amount of sealant was required and applied at an area to avoid any of the above defects from occurring. If any lapse or error occurred, then, it led to a leakage in various compartments of the car. Hence, performing a sealing operation required a skilled and trained operator.

Simulanis Solution

A fully immersive, power pack Virtual Reality (VR) training module of the whole sealing operation simulated as per the Standard Operating Procedures (SOP) of the plant was developed by Simulanis. It not only provided an unparalleled level of understanding of the Sealing Operation but also honed and refined the skills of the user.

It allowed the operators to practice the sealing operation in a more challenging and complex environment. This in turn, helped them in perfecting their hand movement which was not possible earlier. It also prevented them from applying any excess sealant and thus, reduced the number of errors during the operation.

Apart from the in-game analytics, intuitive instructional design and a visually appealing UI/UX, the main highlight of the module was it’s ‘learn by doing approach’.