Scenario description:

XR can create more immersive experiences for people at work in order to make their job safer, by providing new ways to be aware of possible hazards and receive more effective, engaging and entertaining training on safety procedures. This is to alert and prevent serious accidents provoked by the co-occurrences of different causes, which can be avoided by conscious collaboration.

SUN unfolds through two complementary use cases, each addressing a key aspect of human–machine collaboration in industrial contexts.

The first use case focuses on safety training and practice, using immersive XR experiences to strengthen awareness and correct use of personal protective equipment (PPE). Through the SUN-SET application and HoloLens2 headsets, workers participate in interactive sessions guided by a virtual avatar, where they learn to identify and apply safety measures in simulated scenarios. This is followed by real-world observation exercises, where AI-based object recognition and real-time visual feedback help reinforce safe behaviors directly on the factory floor. The result is a hands-on, engaging approach to safety education that bridges theory and practice.

The second use case introduces the PRIORI-XR algorithm, designed to dynamically manage task prioritization and workflow optimization. By integrating sensor and camera data, the system continuously updates work orders and displays them through the XR interface, supporting decision-making in fast-paced production environments. Workers can visualize priorities directly within their field of view, reducing cognitive load and fostering smoother coordination across the production line.

From a technical standpoint, the pilot integrates a modular client–server architecture with AI-based image recognition, gesture-based interaction, and cybersecurity monitoring. This combination ensures adaptability, data integrity, and robust operation across different industrial scenarios. The iterative design process involved close collaboration between engineers, human factors experts, and operators, ensuring that technological refinements aligned with real user needs.

The validation process unfolded in two main stages.

An initial round of testing was conducted with SUN consortium staff, enabling the fine-tuning of gesture precision, system responsiveness, and visual ergonomics.

The second phase extended to FACTOR factory operators, who used the system in actual production conditions. Their feedback was highly positive, emphasizing comfort, engagement, and perceived usefulness especially in improving training motivation and task clarity. Challenges such as occasional gesture misrecognition were progressively mitigated through successive software iterations and recalibration of recognition thresholds.

By the end of the validation phase, the pilot had matured into a stable and functional XR environment capable of supporting daily industrial operations. Beyond technical success, it demonstrated a cultural shift toward more human-centered digital transformation, where technology empowers rather than replaces the worker.

Pilot 2 thus stands as a clear validation of the SUN vision: embedding XR and AI not just as efficiency tools, but as enablers of safer, smarter, and more socially connected workplaces.

On YouTube SUN channel you can watch a video showing the validation performed in Versilia Hospital.