- Complexity of Line Clearance
- Consistency and High Turnover
- Quality Control
- Over 16,000 training sessions completed in 10 months
- Significant improvement in procedural accuracy
- Enhanced trainee engagement and knowledge retention
- Elimination of safety risks during training
- Consistent training delivery across all shifts and locations
The Challenge
Line clearance in medical device manufacturing requires absolute precision—a single oversight can trigger:
🔴 Regulatory violations
🔴 Product recalls
🔴 Patient safety risks
Traditional training methods struggled with hands-on limitations: live training posed safety risks, Traditional training lacked engagement, and high turnover made consistency difficult. With limited access to equipment and tight production schedules, trainees often entered real-world operations underprepared. The need was clear—a way to practice high-stakes procedures safely, repeatedly, and at scale.
The Solution
To address these challenges, an immersive VR training program was developed using the Avatar Academy platform. The solution recreated a true-to-life cleanroom environment where trainees could interact with virtual equipment using natural hand movements—no controllers needed. Structured learning modules broke down the process into guided education, hands-on practice, and competency exams. Unlike traditional methods, this approach allowed unlimited risk-free repetition, standardised training across locations, and real-time performance tracking. Most importantly, it integrated Manufacturing Execution System (MES) workflows, mirroring actual production line protocols. Over 16,000 sessions were completed in just 10 months, proving both adoption and scalability.
The confidence gained through VR training is unbelievable—when comparing those without the training to those who have it, the difference is huge.Alexandra Babiarz, Subject Matter Expert, Boston Scientific Cork
Measurable Outcomes
The implementation demonstrated clear benefits:
- Unprecedented Adoption: Over 16,000 training sessions completed, demonstrating rapid workforce acceptance and scalability.
- Improved accuracy: Notable reduction in procedural errors (exact metrics remain proprietary)
- Risk mitigation: Elimination of training-related safety incidents
- Efficiency gains: Faster competency achievement versus traditional methods
- 100% safety compliance with risk-free VR practice
- 0% contamination events from training
Why This Matters for Regulated Industries
This successful implementation highlights VR’s unique value for:
✔ Compliance training – Meets strict regulatory requirements
✔ Knowledge transfer – Captures and standardizes best practices
✔ Operational efficiency – Reduces training time and costs