As hijackings of aircraft increase in number and sophistication, it’s ever more apparent that the old training approaches based on static exercises and outdated guides don’t provide sky marshals with sufficient training to face the unpredictable, high-stakes environment of a crisis, a gap that becomes deeply felt when each second could decide the fate of thousands of lives. To fill this vital gap, we introduce the Counter Hijacking Simulator System (CHSS), a well-planned solution for transforming preparedness, it employs the YOLOv5 algorithm for high-speed, pinpoint weapon detection, a Raspberry Pi to monitor hijacker movement in real time with accuracy, and Unity to develop immersive, real-world simulations reflecting the tension of an in-transit threat—further empowered by AI which mimics attacker behaviour, initiates non-lethal tranquilizer deployment to quell threats, and notifies officials if no course of action is initiated within 15 s, all made possible at a reduced cost and compatible with changing demands. The early results are reassuring: security staff are exhibiting quicker, more assertive decision-making, greater coordination, and increased resilience when confronted with highly intense, real-world simulations, indicating that CHSS not only meets current pressing requirements but also establishes a strong foundation for future support of aviation security for many years to come.