Background: Simulation is a useful method to improve learning and increase the safety of work operations, both for technical and non-technical skills. However, the observation, assessment, and feedback about these skills is particularly complex, because the process needs expert observers, and the feedback could be judgmental and ineffective. Therefore, a structured process to develop effective simulation scenarios and tools for the observation and feedback about performance is crucial. To this aim, in the present research, we developed a training model for electricity distribution workers, based on high fidelity simulation. Methods: We designed simulation scenarios based on real cases, developed, and tested a set of observation and rating forms for the non-technical skills behavioral markers, and we tracked behaviors based on non-verbal cues (physiological and head orientation parameters). Results: The training methodology proved to be highly appreciated by the participants and effective in fostering reflexivity. An in-depth analysis of physiological indexes and behaviors compliant to safety procedures revealed that breath rate and heart rate patterns commonly related with mindful and relaxed states were correlated with compliant behaviors, and patterns typical of stress and anxiety were correlated with non-compliant behaviors. Conclusions: a new training method based on high fidelity simulation, addressing both technical and non-technical skills is now available for fostering self-reflection and safety for electricity distribution workers. Future research should assess the long-term effectiveness of high-fidelity simulation for electricity workers, and should investigate non-invasive and real-time methods for tracking physiological parameters.