Case Study: Wood Processing Industry

Challenge

The client – a company in the wood processing industry involved in the production of particle boards, plywood, and furniture components, employing over 500 workers. The plant is characterized by high risks associated with operating heavy machinery, sharp tools, and flammable materials such as wood dust. In the past, accidents occurred due to insufficient knowledge of emergency procedures and safety rules. Examples include fires caused by dust ignition, accidental cuts, and equipment failures leading to severe injuries. The company needed a comprehensive solution to improve workplace safety and reduce the risk of accidents in production areas. Proposed Solution

To address the challenge, an innovative training program was designed and implemented, combining modern technologies with the practical needs of the industry. The program included three key elements:
  1. E-learning training on occupational safety and equipment operation
    • Employees gained access to an e-learning platform presenting theoretical foundations of workplace safety in the wood processing industry. Training modules included:
      • Safety in operating saws, planers, and other machinery.
      • Risk management related to wood dust and flammable materials.
      • Procedures for machine malfunctions and first aid in case of accidents.
      Upon completing the course, each participant took a test to verify their knowledge.
  2. VR training simulating emergency situations
    • After passing the e-learning course, employees participated in VR training that allowed them to realistically practice emergency scenarios. Virtual environments included:
      • Extinguishing a simulated fire caused by wood dust ignition.
      • Emergency shutdown of machinery in case of malfunction.
      • Safe evacuation from areas threatened by fire or chemical leaks used in wood processing.
    Thanks to the ability to repeatedly practice scenarios, trainees had the opportunity to develop proper reactions to various crisis situations.
  3. Monitoring progress and analyzing training effectiveness
    • All participant results were recorded in the LMS system.
    • Occupational safety departments and management had access to detailed reports that identified areas needing additional training.
    • The system also allowed assessment of the overall safety level in the plant.

Results Achieved

Implementing the program brought significant benefits to the company:
  1. Reduction in the number of accidents: The number of reported incidents decreased by 35% within a year of implementing the program.
  2. Increased employee readiness: The average response time to emergencies was reduced by 40%, enabling quicker mitigation of potential hazards.
  3. High knowledge retention: 92% of training participants scored above 85% in final theoretical and practical tests.
  4. Improved safety culture: 88% of employees rated the training program as useful and motivating for greater safety awareness in surveys.

Conclusions

Modern training programs that combine e-learning with VR technology have significantly improved safety levels in the wood processing plant. Realistic training scenarios helped employees master appropriate responses to crisis situations, leading to a substantial reduction in accident risk. This program can be successfully adapted in other processing plants, enhancing workplace safety across the industry.

Potential Applications in Other Industries

A similar program can be applied in industries such as:
  • Furniture manufacturing – machine operation and emergency response training.
  • Forestry – safe tree felling and chainsaw use training.
  • Production plants (including those working with steel, stainless steel, and others) – mitigating risks associated with machine operation.
Thanks to the flexibility of VR technology, the program can be tailored to the specific needs of various industrial sectors, enabling more effective workplace safety management.