Vedanta Aluminium, India’s largest aluminium producer, is using artificial intelligence (AI), Industrial Internet of Things (IIoT), advanced analytics and digital safety systems to improve manufacturing, logistics, asset management and workplace safety across its operations. The company is deploying digital technologies to improve visibility, strengthen safety and support faster decision-making across its plants. The initiatives are aimed at helping teams identify risks early, improve operational reliability and make better use of resources.
At Bharat Aluminium Company (BALCO) in Korba, Chhattisgarh, four AI-enabled Control Towers have been deployed to manage key areas of the logistics network. The systems combine GPS, IoT-based vehicle tracking, video telematics, geo-fencing and real-time analytics.
The Control Towers monitor coal movement, finished goods deliveries and ash management. By bringing information from different logistics activities onto a connected platform, the system provides greater oversight of vehicle movement and material handling.
At Vedanta Aluminium’s Lanjigarh refinery in Odisha, technology is also being used to strengthen safety training. The refinery has introduced ‘Aluminati’, an AI-powered robot designed to make safety learning more interactive and accessible. It provides real-time guidance and multilingual support while helping employees access digital learning resources.
The company has also introduced Heavy Motor Vehicle (HMV) Driver Simulator Training. The simulator provides drivers with a realistic and risk-free environment to improve hazard identification, emergency response and safe driving practices.
“Technology is increasingly becoming an integral part of how modern industries approach safety, operational excellence and productivity. Our focus is not simply on adopting new technologies, but on applying them to solve real operational challenges,” said Rajesh Kumar, CEO, Vedanta Aluminium. At Jharsuguda, the company is using AI, machine learning, advanced sensors, digital twins and asset-health analytics in manufacturing operations. These technologies provide continuous monitoring of critical processes and assets, replacing dependence on periodic inspections with real-time information and predictive insights.
The company said the use of connected technologies across its operations is helping improve process reliability, resource utilisation, safety and operational decision-making. Vedanta Aluminium operates integrated assets including an alumina refinery, a major aluminium smelter complex in Odisha and BALCO. The company supplies a wide range of aluminium products to customers in more than 60 countries and is working to expand the use of technology across its manufacturing value chain.
