# Virtual Reality and Digital Twins for Catastrophic Failure Prevention in Industry 4.0
## 2 Materials and Methods
### Methodological Proposal  
In Figure 2, the proposed workflow is presented, detailing the sequential tasks, tools involved and expected outputs for the implementation of the digital twin and early warning system in a VR environment. For the development of a technological implementation of this type, a sequence of steps was designed to allow the inclusion of the technological solution, allowing, in the first instance, the selection of the equipment to which this technology will be applied under defined criteria and guidelines. Figure 1: Methodology. The first step is to analyze the equipment environment and the possible risks that its handling could represent for operators and technicians. To do this, it is essential to perform a HAZOP analysis (Hazard and Operability Analysis), a systematic methodology to identify deviations in the operation of the different pieces of equipment involved in a production process and to evaluate their possible consequences. This analysis facilitates the implementation of appropriate mitigation measures, ensuring a safe working environment and optimizing the integration of technology in industrial operation. The inclusion of HAZOP analysis makes it possible to determine the need for the soundproofing of factors external to the machine, with the aim of preserving the integrity of the workers. The identification of noise sources or interferences in the working environment is crucial, as they can affect both safety and operational efficiency. In this context, the combination of HAZOP analysis with virtual reality technologies enables the simulation of different working conditions, allowing the evaluation of corrective and preventive measures in different types of scenarios. This reduces risks, improves personnel training and optimizes maintenance and operation processes [8]. Once the HAZOP analysis has been performed, it is essential to carry out a detailed study to identify which parts or systems of the equipment should be parameterized according to the occurrence of failures and the criticality of each component for the correct operation of the equipment. For these purposes, in an industrial environment it is recommended to perform a Failure Mode and Effect Analysis (FMEA) or its extended version, the Failure Mode, Effect and Criticality Analysis (FMECA) [14]. FMEA is a structured methodology used in reliability engineering to identify and evaluate the possible failure modes of a system and their causes and effects, with the objective of mitigating possible risks before they occur. FMECA allows the extension of FMEA by including a criticality assessment, being able to prioritize failure modes according to their impact on operation and safety [15]. Including FMEA- or FMECA-type analyses in the initial phase of the process allows users to achieve the following:  
* Identify potential faults in key equipment components prior to implementation. Figure 2: The workflow diagram of the proposed methodology for implementing a digital twin with virtual reality and early warning capabilities. Each stage includes the specific tools employed and the expected outcomes, enabling a structured integration of monitoring, training and predictive maintenance technologies under Industry 4.0 paradigms. * Evaluate the severity and probability of the occurrence of each possible fault, prioritizing those with the greatest impact. * Optimize equipment parameterization, ensuring that critical variables are adequately monitored. * Reduce maintenance costs and unexpected downtime by implementing preventive and predictive maintenance strategies. * Improve industrial safety, minimizing risks for operators and technicians. The combination of analysis in conjunction with digital tools, such as virtual reality and digital twins, allows users to simulate faults and evaluate maintenance strategies in a virtual environment before applying them in the real world [16].