The RepAlreality project, funded under grant 03WIR2508B by the WIR! alliance, ran from 1 June 2021 to 31 May 2023. It was a joint effort between the engineering company IEK, a business unit of VINCI‑Energies Deutschland, the power‑substation operator Omexom, and the research institute BTU Cottbus‑Senftenberg. IEK designed and produced the virtual‑reality training scenario “Working on a medium‑voltage switchgear”, Omexom supplied the industrial sites and personnel for the training, and BTU carried out the on‑site observations, questionnaire administration, and statistical analysis of the data.

The training was introduced after a kick‑off meeting on 24 June 2021 and the first VR scenario was finalized on 2 November 2021, allowing the start of the 2022 training sessions. Eighty‑five employees from six business units—Bautzen/Dresden, Rutesheim, Zwickau, Berlin, Spremberg, and Cottbus—participated. Each trainee completed a pre‑training questionnaire, a post‑training questionnaire, and an online follow‑up survey six months later to assess reports of unsafe situations (MUS) and safety‑related behaviour. Observations were made before, during, and immediately after each VR session.

The baseline survey revealed a relatively high safety culture across the units but a generally low technology affinity. Interest in VR was neutral to slightly positive. After spending more time in the VR environment, participants reported a stronger prioritisation of safety in their work and, six months later, a noticeable increase in technology affinity. The data also showed that employees who spent more time in VR reported more incidents and, simultaneously, a reduction in actual accidents during the observation period. Mild dizziness and slight discomfort were reported by a few users, but overall the VR experience and equipment handling were rated very positively. Statistically significant improvements were found in participants’ interest in VR, willingness to use the technology, satisfaction with the training method, and the number of reports of unsafe situations. Fears and uncertainties were also significantly reduced.

These findings confirm that VR can enhance safety training effectiveness, especially for workers with varying levels of qualification. The project demonstrated that a digital training module can be integrated into existing safety programmes, reduce training time for complex, high‑risk equipment, and provide a competitive advantage by lowering accident and near‑miss rates. The positive acceptance and high willingness to adopt VR among the trainees led the partners to plan further scenarios and broader implementation across the Omexom Transformation Group.

In summary, RepAlreality achieved its technical objectives by delivering a realistic, immersive training scenario that statistically improved safety awareness and reporting behaviour. The collaboration between IEK, Omexom, and BTU, supported by the WIR! alliance, proved effective in combining industrial application, academic research, and practical deployment within the two‑year project window.