PLANT RELIABILITY.
Equipment Faults + Process Anomalies
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PlantOS™ Prescriptive AI.
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3 outcomes in 1 prescription — zero guesswork.
Eliminated
Acted Upon
9,055 critical equipment
Savings
FROM NOISE
TO OUTCOMES.
Mechanical Faults
Vibration, wear &
bearing degradation
Physics + AI models detect gearbox bearing defects, pinion-to-girth gear misalignment, and structural looseness across Ball Mills, Potline Belt Conveyors, and Vibrating Screens before they cascade into unplanned downtime — protecting throughput across mining, smelting, and metals operations.
Electrical Faults
Motor overheating &
drive anomalies
Temperature and vibration trend analysis at fan DE and NDE bearings surfaces inadequate lubrication conditions and load imbalances before they trip critical Potline ID Fans, FRP fans, and Rodding line drives.
Process Induced Faults
Parameter drift &
production deviation
Continuous 24×7 condition monitoring — combining advanced MEMS and piezoelectric sensing — across Ball Mill circuits, Cast House equipment, and Conveyor Belts & Rollers detects process shifts before they impact yield or energy efficiency, and before they reach the next stage.
489 areas. 9,055 critical equipment. One Single Source of Truth.
How Vedanta scaled from 350 sensors at VAL Jharsuguda in 2021 to 26,341 monitoring locations across 77 plant sites worldwide — unifying Vedanta Aluminium, Hindustan Zinc, and Sesa Goa operations across Potlines, Ball Mills, Vibrating Screens, Rodding lines, and Cast Houses into a single contextualized source of truth.
Contextualization layerPhysics + AI: precision that predictions can't match
PlantOS™ doesn't flag anomalies. It traces root cause — across mechanical, electrical, and process domains — with 99.98% accuracy. Advanced MEMS and piezoelectric sensing combined with domain experts who review and validate every prescription — precision that built confidence across Vedanta's reliability leadership.
Intelligence layerDiagnostic → Recommendation → Action
1,554 prescriptions acted upon at an 83.64% user-validation rate. Digital workflows and remote diagnostics reduced manual inspections in hazardous areas and accelerated work order execution — not dashboards, not alerts. Work orders that close.
Prescriptive engineOutcomes the plant's own operators signed off on
5,039 hours of unplanned downtime eliminated. 5,206 hrs MTBF achieved over the last 12 months. >$700K USD in production savings at HZL across mines & smelters. Higher availability across Potlines and Ball Mills. All figures validated by Vedanta's own Reliability & Operations teams.
Validated outcomesPrediction
≠
Outcomes.
Most AI deployments stop at the alert. They predict. They visualize. They dashboard. But prediction without a closed loop is just a more expensive alarm bell.
Vedanta’s deployment with PlantOS™ proves the gap isn’t in the model — it’s in the mile between insight and action. The 99% Trust Loop™ is what bridges it. And at Vedanta scale — 77 plants, 9,055 critical equipment, 26,341 monitoring locations across the global portfolio — the results don’t just compound. They scale from local initiative to group strategy.
Since partnering with Infinite Uptime, we’ve seen a significant boost in plant availability and reliability. The ability to detect issues early has not only helped us avoid costly downtime but also built confidence in our operations. With these results, we’re now moving into phase two — nearly doubling our sensor coverage to monitor the entire plant.
Mr. Gaurang Kamat
Head Engineering, Sesa Goa, Vedanta Group, India
GET THE COMPLETE PICTURE.
The numbers above are the headline. The full story reveals the real challenges Vedanta faced — FY21–22 breakdowns in Potlines and Ball Mills at flagship sites like VAL Jharsuguda, high maintenance costs, safety risks from intensive man–machine interaction in hazardous areas — and exactly how PlantOS™ flipped the script, scaling from 350 sensors at one plant to 26,341 monitoring locations across 77 sites and transforming reliability from a local initiative into group strategy.
Real PlantOS™ Diagnostic Reports from live Vedanta deployments — HZL Ball Mill R4, Potline FRP ID Fans
Equipment-level fault detection across mechanical, electrical & process domains
The 99% Trust Loop™ framework — step by step
User-validated outcome data, confirmed by Vedanta's Reliability & Operations team.
Thank you for your interest in
PlantOS™ Prescriptive AI.
Enter your official work email to unlock specs delivering
3 outcomes in 1 prescription — zero guesswork.
Infinite Uptime × Vedanta Group
A PlantOS™ Transformation Story · Production Outcomes. Delivered.
