Sanofi uses the industrial metaverse to revolutionize training and operational efficiency

Sanofi revolutionizes employee training and operational efficiency with HoloLens 2 and Remote Assist

As a global leader in the production of prescription medicines, vaccines, and consumer health products Paris-based Sanofi is dedicated to improving people’s lives.  Safely processing and packaging its diverse array of products is integral to Sanofi operations—and its commitment to customers. From tracking batches and batch changes, to monitoring the environment to minimize the impact of moisture, light, and oxygen on drug efficacy and shelf life, the process is complex and requires significant training for employees.

In recent years, Sanofi has faced increasing market demand for its products and needed more agile and efficient training methods to support higher production volumes. Traditional training processes were time-consuming and required tutor assistance, leading to inconsistencies. The objective was to leverage the industrial metaverse to standardize training, reduce training time, and improve overall performance.

Standardizing training and deploying globally

Antoine Capelle, Production Team Manager at the Sanofi packaging workshop in Lisieux, led a pilot project to implement Microsoft HoloLens 2 with Dynamics 365 Guides and Remote Assist to streamline employee training procedures, enhance operator efficiency, and integrate a digital approach within the manufacturing environment.

“Training through digitalization is important—why? Because training is something that needs to always be done the same way,” says Capelle. “Rather than repeating the same approaches several times or risking error with each operator doing something a little differently, we knew we could standardize and deploy training globally with HoloLens 2.” 

Capelle transcribed the company’s entire paper batch change procedure into a digital version for HoloLens 2. He then programmed HoloLens 2 to create an interactive hands-on training experience in the industrial metaverse for the company’s operators in three areas: production operations (including batch changes), environmental and safety operations, and electrical maintenance. “Batch changes are significant. When you switch from one product to another there is no room for error. We have safety training to make the operators aware, ensuring safety in the line where they work and across the workshop,” says Capelle. 

Adds Lefevre, “We do batch changes every day on our packaging lines, and in previous training sessions, it doubled the batch change time.” HoloLens 2 reduces that time for training, which Lefevre says is a “real gain in performance when every box produced is important for our patients.”

Promoting independent learning in the metaverse

While new employees can learn their tasks using HoloLens 2, former employees can use the glasses to hone and develop their skills. Operators can train independently without requiring a dedicated tutor, freeing them for other tasks and enhancing operational efficiency. Using HoloLens 2, Sanofi has reduced training time for new operators from eight weeks to six weeks. 

“The methodology is much better, and the education is solid. Reducing training time by two weeks compared to training with a tutor. It saves time operationally and we don’t have to replace an operator with a temporary worker during training,” says Capelle. The organization is also using HoloLens 2 for remote maintenance and troubleshooting, enabling quicker resolution of equipment issues.  “With the technology we can communicate and collaborate with each other across the workshop or with our colleagues in different locations, much as we would in person—this is the beauty of metaverse.” 

For example, the workshop experienced an equipment breakdown that required communication with Germany. “We had HoloLens 2 and were able to work with that team to troubleshoot the machine much faster. It was an extraordinary win for us,” says Capelle. And, he adds, points to what the company can do in the future across all of its locations.

“The devices have helped us introduce a visual, didactic, and pedagogical method of training that breaks away from traditional classroom-style training,” says Christophe Lefevre, Production and Maintenance Site Manager at Sanofi. “With it, operators can develop muscles pretty easily.” 

Capelle agrees, “Because it’s the same operating principle as a Windows screen on a Windows PC, everyone gets used to it quickly. The equipment is very light, and it frees your hands for uninterrupted work and learning.” This modern approach is also helping the company attract new and younger talent which is important for the company’s immediate growth and longevity.

Expanding deployment for greater innovation

Employee feedback on the HoloLens 2 pilot has been positive. Operators say they appreciate the visual, user-friendly, and standardized training experience and Lefevre says the goal now is to expand deployment to other production lines. 

“We need to democratize the deployed tool a little more—and keep using it beyond the training,” Lefevre says. The company has plans for expansion across several departments and use cases, with a specific emphasis on data analysis. 

“I'm happy with what we've done, but we are only at the beginning of mixed reality in this industry,” says Lefevre. “For sure, it's a revolution—and we see the value HoloLens 2, the metaverse can bring to every aspect of our operational chain. Ultimately it will help deliver even more in our commitment to supporting better health and well-being for our customers.”  

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