BALCO Strengthens Safety with Humanoid ALAISA on the Shop Floor
15th April 2026
Balconagar, 15th April 2026: Bharat Aluminium Company Limited (BALCO), India’s iconic aluminium producer and a unit of Vedanta Aluminium, has deployed ALAISA (Aluminium AI Support Agent), a first-of-its-kind humanoid, AI-powered assistant designed to enhance shop-floor capability, operational efficiency, and industrial safety in aluminium manufacturing.
Currently operational at BALCO’s smelter complex in Chhattisgarh, ALAISA functions as an on-ground training, knowledge, and decision-support interface for shop-floor teams. The system integrates conversational AI with plant-specific operational intelligence to deliver contextual, real-time guidance on Standard Operating Procedures (SOPs), Standard Maintenance Practices (SMPs), and critical safety protocols, directly at the point of operation.
Speaking on the development, Rajesh Kumar, CEO & Director, BALCO, said, “Technology and innovation remain central to BALCO’s vision of building a future-ready aluminium ecosystem. The introduction of ALAISA reflects our commitment to leveraging artificial intelligence and digital solutions to strengthen operational excellence and workforce capability. By enabling real-time learning, knowledge access, and process guidance, such technologies empower our teams to perform with greater confidence and efficiency, strengthening industrial capabilities and supporting the journey toward technology-driven growth.”
In its initial phase, ALAISA has trained over 100 employees. It supports structured learning modules, real-time query resolution, and built-in, assessment-driven evaluations that enable supervisors to monitor comprehension levels and skill progression. By embedding continuous, data-driven learning into the shop-floor environment, the system is helping standardise processes, strengthen safety compliance, and enhance workforce readiness in high-intensity industrial settings. Early employee feedback indicates improved access to technical knowledge, faster resolution of operational queries, and greater confidence in decision-making during live operations.
Sharing his experience of interacting with ALAISA, Uday Chauhan, PGT, BALCO, said, “Before beginning my work at the potline, I underwent safety training on standard operating procedures through ALAISA. It was a remarkable experience. Despite being a robot, the training was as effective as that delivered by a human trainer.”
The deployment marks a significant milestone in India’s metals sector, positioning BALCO among early adopters of humanoid AI systems in core manufacturing. The company is among the first in India, and one of the few globally, to implement Digital Smelter technologies, enabling predictive and prescriptive analytics.
ALAISA forms part of the company’s broader digital transformation journey, spanning the supply chain, potline operations, cast house, rolled products, and carbon facilities. These integrated initiatives are focused on leveraging advanced analytics, automation, and intelligent systems to improve operational efficiency, optimise resource utilisation, enhance product quality, and strengthen safety performance.
About BALCO:
Bharat Aluminium Company (BALCO) is a subsidiary of Vedanta Limited, operating a 0.57 million tonne per annum aluminium smelter in Korba, Chhattisgarh. It is part of Vedanta’s Aluminium Business, a division of Vedanta Limited, which is India’s largest producer of aluminium, manufacturing more than half of India’s aluminium, i.e., 2.42 million tonnes in FY25. It is a leader in value-added aluminium products that find critical applications in core industries. Vedanta Aluminium ranks 2nd in the S&P Global Corporate Sustainability Assessment 2024 world rankings for the aluminium industry, a reflection of its leading sustainable development practices. With its world-class aluminium smelters, alumina refinery and power plants in India, the company fulfils its mission of spurring emerging applications of aluminium as the ‘Metal of the Future’ for a greener tomorrow. For more information, please log on to
www.balcoindia.com
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Disclaimer:
This press release contains “forward-looking statements” – that is, statements related to future, not past, events. In this context, forward-looking statements often address our expected future business and financial performance, and often contain words such as “expects,” “anticipates,” “intends,” “plans,” “believes,” “seeks,” “should” or “will.” Forward-looking statements by their nature address matters that are, to different degrees, uncertain. For us, uncertainties arise from the behaviour of financial and metals markets including the London Metal Exchange, fluctuations in interest and or exchange rates and metal prices; from future integration of acquired businesses; and from numerous other matters of national, regional, and global scale, including those of a political, economic, business, competitive or regulatory nature. These uncertainties may cause our actual future results to be materially different than those expressed in our forward-looking statements. We do not undertake to update our forward-looking statements.
About Vedanta Limited:
Vedanta Limited, a subsidiary of Vedanta Resources Limited, is one of the world’s leading Oil
& Gas and Metals company with significant operations in Oil & Gas, Zinc, Lead, Silver,
Copper, Iron Ore, Steel, and Aluminium & Power across India, South Africa, Namibia, and
Australia. For two decades, Vedanta has been contributing significantly to nation building.
Governance and sustainable development are at the core of Vedanta's strategy, with a strong
focus on health, safety, and environment. Giving back is in the DNA of Vedanta, which is
focused on enhancing the lives of local communities. Under the aegis of Vedanta Cares, the
flagship social impact program, Nand Ghars have been set up as model anganwadis focused on
eradicating child malnutrition, providing education, healthcare, and empowering women with
skill development. Vedanta and its group companies have been featured in Dow Jones
Sustainability Index 2020, and were conferred Frost & Sullivan Sustainability Awards 2020,
CII Environmental Best Practices Award 2020, CSR Health Impact Award 2020, CII National
Award 2020 for Excellence in Water Management, CII Digital Transformation Award 2020, ICSI
National Award 2020 for excellence in Corporate Governance, People First HR Excellence Award
2020, ‘Company with Great Managers 2020’ by People Business and certified as a Great Place
to Work 2021. Vedanta’s flagship Nand Ghar Project was identified as best CSR project by the
Government of Rajasthan. Vedanta Limited is listed on the Bombay Stock Exchange and the
National Stock Exchange in India and has ADRs listed on the New York Stock Exchange.
For more information, please visit
www.vedantalimited.com
