From the furnace to the lockout padlock,
every step practiced off the line.
Simulators for the processes in your steel mill, from the electric arc furnace to the cranes in the bay, built on your own equipment and your procedure.
All of them live on one platform with a per-person report, and the program grows one module at a time.
Every module follows your plant's procedure. These come from the Gerdau Corsa program, which has eleven.
Trained in its control room, with the panel, the valves and the button sequence.
Maneuvering over the furnace from the cab, with the floor in full view.
The padlock goes on the panel with the glove on, and the full procedure repeats as many times as it takes.
A 360 video takes each new person through the plant before they set foot in it.
Module eleven: a single catalog operators enter from, where the per-person report and the results ranking are kept.
Overhead crane with magnet, scrap crane with grab, logistics, molten metal ladle and casting, each with its physical controls, plus floor-level rigging.
See the overhead crane simulatorThree processes that keep running while your people learn them.
While the electric arc furnace works, a new operator learns the control room in the headset: the panel, the valves and the button sequence your procedure calls for. They sit down at the panel with that sequence already rehearsed.
The ladle crosses the bay over people and equipment, and the pour gets a single window. In the simulator that move repeats with the view from the cab and the crane's levers until it comes out clean.
Loose material moves under the magnet or the grab. Operators practice it from the cab before working the yard.
This is how the Gerdau Corsa program grew, on one architecture. Your mill can start with a single piece of equipment.
Pick the process where a mistake costs the most. Gerdau Corsa began with overhead cranes, their physical controls wired into the simulation.
That base grew to six cranes, from the scrap magnet to the cab above the furnace, and each one kept its own levers while inheriting the architecture of the first.
Floor-level rigging, the electric arc furnace, lockout/tagout and the 360 induction came next.
It is module eleven, and every new piece of equipment joins the same catalog with its per-person report.
How each process is learned today, and how it is learned in the simulator.
| On the line | In the steel mill simulator | |
|---|---|---|
| Where people practice | On the equipment that produces, whenever it is free | In the headset, off the line |
| The furnace control room | With the furnace running and someone alongside | Panel, valves and button sequence rehearsed in the headset |
| Lockout/tagout | Done on the plant's panel when the job comes up | The full procedure, padlock and glove included, as often as needed |
| The first day in the plant | A safety talk before walking into the bay | A 360 walk-through before setting foot in it |
| Production | Gives up the equipment or slows down while someone learns | Keeps its schedule |
| What stays on record | The signature of whoever shadowed | A per-person report and a ranking on one platform |
To put a number on the first column, the operator training cost calculator adds up the weeks on the equipment, the shadowing and the ramp to full pace.
In seven years the program grew from one family of crane simulators to eleven modules: six cranes, the floor-level overhead crane, the electric arc furnace, lockout/tagout, a 360 induction and the platform that hosts them.
Program catalog, August 2026.
Figure reported by the plant.
Practice happens away from the equipment.
Yes, because it is built on your own equipment. The crane is modeled from photos, drawings or CAD with the view from your cab, and the furnace module follows the panel and the sequence of your control room. The brand matters less than your procedure, which defines an error and how each attempt is scored.
On the cranes, yes: in the Gerdau Corsa program each crane has physical industrial controls wired into the simulation, so the operator works the same levers as in the cab. The program also uses Meta Quest controllers.
About three months for a custom training simulator and three to six months for a complex project, per our 2026 pricing guide. Each new module is added on the same architecture. If you want your own numbers first, a Diagnostic Pilot takes about 3 weeks.
More questions
Tell us what you want to solve in your plant. Fyware designs extended reality around the equipment and constraints of your operation, and builds it to grow from a pilot to the whole site.
Tom Klukowski, Fyware Partner · Valcre Marketing We reply in under 24 business hours, with scope, timeline and investment range.In the meeting you see the simulator running and what it would take to bring it to your plant, with scenarios adapted to your layout. And if you need to sell it internally, this page is your presentation: share it with your team.
