BALCO Deploys AI Humanoid for Smelter Operations

14 Apr 2026 CW Team

Bharat Aluminium Company (BALCO), a unit of Vedanta Aluminium, has deployed ALAISA (Aluminium AI Support Agent), a humanoid AI-powered assistant to strengthen shop-floor capability, operational efficiency, and safety in aluminium manufacturing.

Operational at its Chhattisgarh smelter, ALAISA serves as a real-time training and decision-support interface, offering contextual guidance on SOPs, maintenance practices, and safety protocols. The system combines conversational AI with plant-specific intelligence to deliver on-ground assistance.

In its initial phase, over 100 employees have been trained using structured modules, real-time query resolution, and assessment-based evaluations, enabling supervisors to track skill progression and comprehension.

The deployment supports BALCO’s broader digital transformation, including AI-led predictive maintenance across 2,000+ equipment points and IoT monitoring across 600 machines. The initiative aims to standardise processes, enhance safety compliance, and build a more skilled workforce in high-intensity industrial environments.

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