Hindustan Zinc Implements First-of-its-Kind AI Solution to Enhance Workplace Safety

AI-Powered ‘Detect AI’ Brings Smart Safety to the Forefront of Mining Operations

Hindustan Zinc Limited (HZL), India’s largest and the world’s second-largest integrated zinc producer, has taken a groundbreaking step in industrial safety with the implementation of ‘Detect AI’, an advanced Artificial Intelligence-powered camera surveillance system. This revolutionary solution significantly enhances workplace safety, operational efficiency, and compliance monitoring.

By replacing manual interventions with AI-driven processes, Hindustan Zinc is leading the way in adopting next-generation safety infrastructure powered by computer vision and machine learning algorithms. This transformation empowers real-time detection of unsafe practices and non-compliance issues, streamlining the operations for better safety outcomes.

Smart Surveillance Powered by Real-Time AI Monitoring

‘Detect AI’ integrates seamlessly with the company’s existing Internet of Things (IoT) infrastructure, drastically reducing the need for manual supervision. By utilizing real-time image and video analysis, deep learning models, and edge computing, this system autonomously identifies violations such as:

• Non-compliance with safety gear protocols

• Unauthorized personnel access

• Lapses in height safety procedures

The system classifies these violations using predictive analytics and triggers automated alerts via a cloud-based AI inference engine, generating rich, actionable, and data-driven insights. With intelligent automation, real-time KPI tracking, and smooth API integration, ‘Detect AI’ is redefining industrial safety by:

• Minimizing incident occurrences

• Improving compliance

• Enabling proactive risk mitigation

Leveraging Industry 4.0 for Operational Excellence

Hindustan Zinc has embraced Industry 4.0 technologies, incorporating AI, ML, automation, and data analytics to unlock high-potential opportunities across its operations. These advancements span key domains such as:

• Process optimization

• Metal recovery

• Asset reliability

• Sustainability

• Productivity

The implementation of advanced AI systems at key mining sites — including Rampura Agucha, Sindesar Khurd, Rajpura Dariba, Zawar, and Kayad — has led to an increase in operational efficiency by 20–30%, while reducing manual interventions by nearly 50%.

Leadership Perspective on Digital Transformation

Highlighting the strategic importance of AI in manufacturing, Arun Misra, CEO of Hindustan Zinc, stated:

“At Hindustan Zinc, we are committed to sustainable and responsible growth. Integrating technological excellence and automation into our operations enables us to reduce manual interventions and adopt advanced solutions like AI, ML, IIoT, and computer vision. This not only places us at the forefront of the industry but redefines our agility and capability to scale innovations within our systems.”

Building a Sustainable and Data-Driven Future

As part of its digital transformation strategy, Hindustan Zinc has also established a first-of-its-kind digital collaboration center. This centralized hub analyzes real-time data from all operational units, enabling robust decision-making backed by deep insights.

The AI-driven computer vision solution is a cornerstone in HZL’s vision for intelligent mining. By collaborating with emerging startups, the company is tapping into:

• Advanced analytics

• IoT sensors

• Real-time diagnostics

• ML-based performance optimization tools

These collaborations aim to generate actionable insights that improve equipment monitoring and enhance productivity across the board.

Global Recognition and Sustainability Commitment

As a Vedanta Group company, Hindustan Zinc is not only a global leader in zinc and silver production but also a front-runner in sustainable mining practices. The company has been recognized as the world’s most sustainable metal and mining company by the S&P Global Corporate Sustainability Assessment 2024 for the second consecutive year.

Additional accolades include:

• Being 2.41x water-positive certified

• Driving the global energy transition by supplying critical minerals essential for a sustainable future