In a step towards smarter manufacturing, Bharat Aluminium Company Ltd (BALCO), a unit of Vedanta Aluminium, has introduced ALAISA, an AI-powered humanoid assistant, at its smelter complex in Chhattisgarh.
ALIASA (Aluminium AI Support Agent) is designed to improve shop-floor efficiency, strengthen safety, and support workers with real-time guidance. The system acts as a training, knowledge, and decision-support tool directly on the shop floor.
It combines conversational AI with plant-specific intelligence to provide instant support on standard operating procedures, maintenance practices, and critical safety protocols at the point of operation.
Quoting Rajiv Kumar, CEO of Vedanta Aluminium, a media statement said: “Digitalisation is fundamentally reshaping manufacturing, and at Vedanta Aluminium, we are embedding advanced technologies into the core operations. The deployment of ALAISA reflects our commitment to building intelligent, future-ready systems that enhance human capability. By combining AI-led insights with shop-floor expertise, we are strengthening safety, improving process reliability, and enabling a more skilled and confident workforce.”
In its initial phase, ALAISA has already trained over 100 employees. It offers structured learning modules, real-time query resolution, and assessment-based evaluations. These features help supervisors track employee understanding and skill development.
By enabling continuous, data-driven learning on the shop floor, the system is helping standardise processes, improve safety compliance, and build workforce readiness in high-intensity industrial environments. Early feedback from employees shows better access to technical knowledge, quicker resolution of operational issues, and increased confidence during live operations.
BALCO is among the first in India and one of the few companies globally to adopt digital smelter technologies. Its operations include AI-led predictive maintenance across more than 2,000 equipment points and IoT-based monitoring across 600 machines.
In mining operations, the use of autonomous drones with geofencing has further improved safety, surveillance, and operational control.
Also read: Viksit Workforce for a Viksit Bharat
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