Vedanta Aluminium brings 4 AI Control Towers into logistics, safety and plant maintenance

Vedanta Aluminium is using artificial intelligence (AI) and other digital tools across its operations as part of its efforts to improve day-to-day decision-making, logistics, safety and equipment monitoring.

At BALCO in Korba, Vedanta Aluminium has introduced four AI-enabled Control Towers to keep track of coal transport, finished goods deliveries and ash management. Using GPS, IoT-based tracking, geofencing, video telematics and real-time data, the system helps teams monitor vehicle movement and manage logistics more closely.

The company is also using AI in safety training at its Lanjigarh refinery. ‘Aluminati’, an AI-powered robot, provides real-time guidance and multilingual support. This makes safety training easier to understand. The plant also uses a Heavy Motor Vehicle Driver Simulator, where drivers can practise handling hazards and emergencies without being exposed to actual risk.

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CEO Rajesh Kumar said, “Our focus is not simply on adopting new technologies, but on applying them to solve real operational challenges.”

At Jharsuguda, the focus is on keeping a closer watch on plant equipment. The smelter is using AI, machine learning, digital twins and asset-health analytics to monitor critical processes and identify potential issues. This allows the company to move beyond periodic inspections and use continuous monitoring to support maintenance decisions.

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Kumar commented, “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,” he added. 

From tracking a vehicle on the road to monitoring equipment inside a smelter, the technologies are now being used across different parts of Vedanta Aluminium's operations. The aim is to bring faster access to information and support safer and more efficient plant operations.