How UltraTech Cement Used AR to Improve Equipment Maintenance Efficiency

Project Overview

UltraTech Cement partnered with KOMPANIONS to modernize its technical training through an Augmented Reality based solution. The training module focused on the cleaning and maintenance procedures for two critical components, the Electrical Grid Resistance Regulator and the Electrical Liquid Resistance Starter.

The solution now serves as a scalable benchmark for AR-driven industrial training.

Client Background

UltraTech Cement is India’s largest manufacturer of grey cement and a leader in building materials. With multiple plants and high-demand production cycles, their operations rely heavily on the proper maintenance of mission-critical equipment.

❓The Operational Challenge

❯ Lack of Interactive Maintenance Training Tools

Traditional SOP-based training was time-consuming and often prone to human error. New staff found it difficult to grasp the complexity of electrical equipment procedures through static manuals alone.

❯ High Stakes in Maintenance Accuracy

Critical machinery like the Electrical Grid Resistance Regulator and Liquid Resistance Starter demand precision and strict adherence to protocols. Any lapse could lead to safety incidents or equipment damage.

💡Our AR Training Solution

❯ AR-Based Step-by-Step Guidance

KOMPANIONS designed an AR experience that overlays real-time, device-specific instructions directly onto the equipment, allowing technicians to follow procedures with confidence and accuracy.

❯ Hands-Free, On-Site Accessibility

Accessible via mobile devices or AR headsets, the solution allows workers to visualize instructions while keeping both hands free—boosting efficiency, reducing errors, and enabling real-time learning.

📊 Key Results Delivered

❯ Key Outcomes Observed:

• ✅ Faster training with real-time visual guidance
• ✅ Reduction in procedural errors and guesswork
• ✅ Improved confidence and independence in new technicians
• ✅ Enhanced equipment uptime through preventive maintenance accuracy

🌍 Why This Matters

Industrial plants like UltraTech are evolving rapidly—and so should training. By introducing AR to complex maintenance workflows, KOMPANIONS helped reduce downtime, boost safety, and support faster knowledge transfer. This model can scale to other plants and maintenance-heavy industries effortlessly.

Looking to modernize industrial training with AR or VR?

Connect with KOMPANIONS today to explore how immersive technology can make your workforce smarter, faster, and safer.