Gulf Logistics Group
VR forklift safety training reducing warehouse incidents by 40% across 5 facilities.
All case studiesGulf Logistics Group operates 5 large-format warehouse facilities across the UAE, handling high-volume freight for retail, automotive, and FMCG clients. Forklift operations are the backbone of their material handling — but also the single largest source of workplace safety incidents. In the 18 months prior to engaging Cydez, the company recorded 47 forklift-related incidents ranging from minor product damage to serious near-misses involving pedestrian workers.
Traditional classroom safety training, delivered as a 2-day induction program, had poor knowledge retention rates. Operators struggled to translate theoretical hazard awareness into real-world decision-making in congested warehouse aisles with limited visibility, tight turning radii, and unpredictable pedestrian traffic.
Cydez developed a suite of immersive VR safety training modules deployed on Meta Quest headsets. Four core scenarios were built: high-density aisle navigation, pedestrian awareness at blind intersections, load stability and stacking, and emergency response (fire, spill, structural collapse). Each scenario adapts difficulty based on operator performance. Reaction times, decision quality, hazard recognition speed, and procedural compliance are scored and reported to supervisors via a React-based analytics dashboard.
- 3D warehouse environment modelling based on actual facility layouts
- VR interaction design and controller mapping for forklift simulation
- 4 core safety training scenarios with adaptive difficulty
- Performance scoring and analytics dashboard
- Meta Quest deployment across 5 warehouse facilities
- Supervisor reporting portal with individual operator progress tracking
A major logistics operator in the UAE experienced frequent forklift-related incidents across 5 warehouse facilities. Classroom safety training had low retention rates and could not simulate the real hazards workers faced daily.
Cydez developed immersive VR safety training modules on Meta Quest headsets — forklift operation in congested aisles, pedestrian awareness, load stability scenarios, and emergency response drills. Performance scores, reaction times, and decision quality are logged and reported to supervisors.
How we delivered this project
Asset Survey
Visited all 5 warehouse facilities to capture floor plans, aisle dimensions, racking configurations, and forklift models. Interviewed safety officers and reviewed 18 months of incident reports to identify the highest-risk scenarios for training prioritisation.
3D Production
Modelled warehouse environments in Blender based on actual facility layouts. Created photorealistic forklift models with functional controls matching real equipment. Built 4 hazard scenarios with dynamic elements — moving pedestrians, unstable loads, and environmental triggers.
Development & Integration
Developed VR training modules in Unreal Engine with Meta Quest SDK integration. Built the adaptive difficulty engine, performance scoring system, and React-based supervisor dashboard. Implemented hand tracking and controller-based forklift operation mechanics.
Testing & Deployment
Piloted with 50 operators at the flagship facility over 3 weeks. Iterated on motion sickness mitigation, control sensitivity, and scenario pacing based on operator feedback. Rolled out to all 5 facilities with on-site training for safety supervisors.
What we built
Immersive Forklift Simulation
Photorealistic VR recreation of actual warehouse environments. Operators drive virtual forklifts with realistic physics, steering response, and load dynamics matching real equipment behaviour.
Adaptive Hazard Scenarios
4 core scenarios — aisle navigation, pedestrian awareness, load stability, emergency response — with difficulty that increases based on operator performance and reaction times.
Performance Scoring Engine
Real-time scoring of reaction time, hazard recognition speed, procedural compliance, and decision quality. Pass/fail thresholds configurable by safety managers.
Supervisor Analytics Dashboard
React-based dashboard showing individual operator scores, team averages, improvement trends, and certification status. Automated alerts for operators requiring retraining.
Multi-Facility Deployment
Centrally managed content updates pushed to Meta Quest headsets across all 5 facilities. New scenarios and difficulty adjustments deployed without on-site visits.
Measurable outcomes
- 40% reduction in warehouse safety incidents within 12 months
- 3x improvement in hazard recognition test scores
- 100% workforce coverage — every operator trained before floor access
- Training time reduced from 2 days classroom to 4 hours VR
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