# Virtual Reality and Digital Twins for Catastrophic Failure Prevention in Industry 4.0
## 1 Introduction
### Issues and Applications
In general, the literature reports multiple advantages of VR-based training: greater commitment and speed in learning, the possibility of measuring performance, scenario customization and cost reduction, all while preserving the physical integrity of the operators by avoiding real risks [5]. Thus, VR is emerging as a present and future alternative for the efficient training of human resources in the industry. For its part, augmented reality offers direct support in the field: with mobile devices or AR glasses, technicians can receive visual instructions superimposed on the real environment during maintenance tasks, facilitating the step-by-step execution of complex procedures [12]. Recent studies show that these AR/VR applications in maintenance tend to improve worker performance--for example, by reducing operation errors--and in most cases the impacts are positive for employees and companies. [PERSON] et al. (2024) identified that well-designed AR/VR solutions increase the efficiency of corrective and preventive interventions [12]. Additionally, AR allows the connecting of remote experts with local operators: by livestreaming the actual scene annotated virtually, a specialist can guide plant personnel in the resolution of a breakdown, combining remote monitoring with real-time expert assistance [12]. This type of AR-based remote support has been successfully tested, showing that it is feasible to perform maintenance with remote expert assistance when on-site access is restricted [13]. In sum, tools such as VR and AR are bridging the skills gap by training and assisting less experienced operators in complex industrial environments [13]. Another technological pillar in Industry 4.0 is the use of digital twins for safety and proactive risk management. The digitization and extensive sensorization of operations open the possibility of automating the monitoring of abnormal conditions and generating early warnings of potential faults or hazardous situations [4]. For example, environmental sensors connected to a digital twin can detect chemical leaks or abrupt changes in process parameters [4]. Likewise, AR/VR is being applied in order to improve personal protective equipment: through visors, a worker can visualize environmental information (temperatures, gas concentrations, etc.) over his or her field of view while operating, increasing situational awareness and safety [4]. These innovations make up what [PERSON] et al. (2022) call Safety 3.0, a new generation of industrial safety management integrated with Industry 4.0 [4]. However, the incorporation of automation in safety must be complemented by the existing safety culture. [PERSON] (2021) warns that relying exclusively on technical solutions (e.g., automated monitoring and warning systems) without involving the human factor could undermine established safety practices [9]. Therefore, they recommend an approach that allows the worker to be included in these processes when implementing Industry 4.0 safety features, where technology serves to empower workers and not displace them [9]. In other words, digital tools should be integrated in a coherent way, supporting informed decision making by operators and maintaining high industrial safety standards. Thus, unlike previous studies that focus individually on remote monitoring, predictive models,or isolated VR training simulators, the present work proposes a structured methodology that integrates all these technologies into a single immersive and interactive system. This approach is novel in that it combines real-time data acquisition from industrial equipment, critical parameter analysis and visual feedback through virtual reality in a training-oriented environment. Furthermore, the methodology is designed using open-source or widely available tools, enabling its cost-effective deployment in educational and industrial settings alike.