Multi-Scenario 3D Safety Animation for a Leading Metal Producer – Hindustan Zinc Ltd. 

Multi-Scenario 3D Safety Animation for a Leading Metal Producer – Hindustan Zinc Ltd.

1. The Premise

Hindustan Zinc Ltd. (HZL), a subsidiary of Vedanta Group and a global leader in integrated zinc, lead, and silver production, operates large-scale smelting and mining operations across India. At its Chittorgarh Pyro Plant, HZL identified a critical need to improve its safety induction and SOP communication for high-risk operational tasks.

To bridge this gap, HZL commissioned CORE-EHS to develop a comprehensive series of 3D animated safety videos focusing on complex, high-hazard industrial scenarios relevant to their core operations.

2. The Challenges

HZL’s EHS leadership faced several persistent training and compliance concerns:

• High-risk scenarios such as hot metal handling, acid plant work, and high-voltage switchyard tasks were difficult to explain through static SOPs or traditional inductions.
• Safety orientation for contractors and technicians showed inconsistencies, with more than 32% of inductees requiring multiple briefings.
• Communication gaps due to varying education levels and regional languages impacted overall safety performance.
• Audit teams flagged a need for more visual, site-specific safety training to reduce behavioral risks and improve preparedness.

The challenge was to build realistic, multilingual animations covering operational specifics while adhering to HZL’s stringent safety norms and policies.

3. The Solution

CORE-EHS delivered a suite of five fully customized 3D safety animation modules, each 6 minutes long, totaling approximately 30 minutes of scenario-based training content.

Modules Covered:

1. Hot Metal Handling
2. Working in Acid Plant Areas
3. Boiler Bundle Replacement
4. Bottom Ash Hopper – Poking
5. Operations in 132 kV Switchyard

Key Features:

• Scripting and storyboarding approved by HZL’s safety and fire officers.
• Use of site-specific images, photos, and operating conditions to boost relevance.
• High-fidelity 3D visuals designed around actual equipment and PPE used on site.
• Bilingual voiceover (Hindi and English) to ensure full workforce accessibility.
• Delivered on physical media (2 DVDs) for easy deployment at induction centers.
• CORE EHS deployed a technical team to Chittorgarh for site assessment and coordination.

The project was delivered on time, and all milestones—20% on script approval and 80% on final submission—were cleared as per payment terms.

4. Resulting Benefits

The animation package was met with excellent feedback and operational improvements:

• Safety induction duration reduced by 38%, enabling more efficient onboarding.
• Over 90% of viewers demonstrated accurate recall of safety steps in post-video assessments.
• Incident trend monitoring post-deployment showed a 27% decline in unsafe behaviors during boiler and acid handling operations.
• The EHS team reported a 44% decrease in repetitive safety explanation tasks, freeing up time for on-ground inspections and improvements.
• The videos are now archived in HZL’s centralized EHS knowledge base and form part of standardized induction at the Pyro Plant.

This collaboration with Hindustan Zinc Ltd. illustrates CORE-EHS’s capability to deliver highly tailored, visually immersive safety training for hazardous industrial domains—turning complex procedures into simple, engaging learning experiences.