Bhubaneswar: Vedanta Aluminium, India’s largest aluminium producer, is leveraging Artificial Intelligence (AI), Industrial Internet of Things (IIoT), advanced analytics and intelligent safety systems across its operations, driving a new generation of connected manufacturing practices.

At Vedanta Aluminium, this digital transformation is translating into practical, on-ground improvements across logistics, production, asset management and workplace safety.

At Lanjigarh in Odisha, digital innovation is being harnessed to strengthen safety culture and workforce preparedness across operations. The refinery has introduced ‘Aluminati’, an AI-powered robot that makes safety learning more interactive, accessible and engaging through real-time guidance, multilingual support and digital learning. Complementing this, theHeavy Motor Vehicles (HMV) Driver Simulator Training provides drivers with a realistic and risk-free environment to enhance hazard perception, emergency response capabilities and safe driving practices.

harsuguda, digital technologies are transforming the way manufacturing operations are managed. By embedding AI, machine learning, advanced sensors, digital twins and asset-health analytics into critical processes, the smelter is enabling real-time visibility across its operations. This shift from periodic inspections to continuous monitoring and predictive insights is helping improve process reliability, optimise resource utilisation and support faster, more informed decision-making.

At BALCO, the company’s iconic smelter based in Korba, Chhattisgarh, this digital-first approach is bringing greater intelligence and oversight to the company’s logistics ecosystem. Four AI-enabled Control Towers deployed at the plant integrate GPS, IoT-based vehicle tracking, video telematics for vehicle management, geo-fencing and real-time analytics to monitor coal logistics, delivery of finished goods and ash management.

Vedanta Aluminum CEO Rajesh Kumar said, “The initiatives undertaken across our plants are creating connected and data-driven operations that enable our teams to anticipate risks, make faster decisions and operate more efficiently. This tech-led transformation is aligned with India’s goal of building globally competitive, resilient and future-ready manufacturing capabilities.”