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Case Study

Digital Twin of Production Facility

Live digital twin of a production facility that transformed operational monitoring and predictive maintenance.

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Operational Readiness XR Training
Program Immersive XR Implementation
Delivery Window 4-Week Validation Pilot
Focus Safety and performance outcomes
Challenge

Fragmented monitoring systems lacked spatial context, making it hard to correlate equipment alerts with physical locations.

Solution

Built a real-time digital twin with live IoT integration, web and VR access, and predictive maintenance dashboards.

Results

Reduced unplanned downtime by 30%, cut maintenance planning time by 50%, and improved cross-team situational awareness.

Project Overview

A chemical processing facility needed better visibility into equipment health and production line status across a sprawling campus. SCADA dashboards provided data but lacked spatial context, making it difficult to correlate alerts with physical locations or plan maintenance efficiently.

HapzXR created a real-time digital twin of the entire facility — a navigable 3D replica connected to live IoT sensor feeds for temperature, pressure, vibration, and flow data. Operators could click any piece of equipment to see its status, maintenance history, and predictive health indicators. The twin was accessible via web browser and immersive VR for different use cases.

Engineering teams used the VR mode for spatial planning and modification reviews, while operations used the web dashboard for daily monitoring. The combined system provided a single source of spatial truth for the entire facility.

Delivery Flow

How This Engagement Was Delivered

  1. 1

    Discovery and Risk Mapping

    Mapped SOPs, operational hazards, and training objectives into a measurable XR scope.

  2. 2

    Scenario Build and Validation

    Developed core simulation modules and validated realism with SMEs and supervisors.

  3. 3

    Pilot Cohort Execution

    Ran structured user sessions with scoring, feedback loops, and targeted remediation.

  4. 4

    Outcome Review and Scale Plan

    Delivered performance insights and rollout recommendations for broader deployment.

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