Aditya Birla – Hindalco: How KOMPANIONS Improved Plant Safety with VR Training for Anode Change

Executive Summary

Hindalco Industries, a flagship company of the Aditya Birla Group, partnered with KOMPANIONS to enhance workforce safety and operational efficiency using Virtual Reality (VR). We designed a customized VR simulation for the Anode Change Process—a critical operation in their potline workflow.

The result? A safer, more efficient, and scalable training program that enabled hands-on learning without real-world risk.

About the Client

Hindalco Industries Limited is one of the world's largest aluminium rolling companies and a global leader in copper. As part of the Aditya Birla Group, Hindalco runs large-scale, high-risk industrial operations requiring strict safety protocols, particularly in processes involving high-temperature and electrically intensive tasks like anode changing.

The Challenge

❯ Operational Risks in the Anode Change Process

The Anode Change Process is both complex and hazardous, involving heavy equipment, electrical hazards, and precise sequencing. Traditional training methods were:

• ⛔ Time-consuming
• ⛔ Dependent on the availability of live equipment
• ⛔ Prone to human error and inconsistent outcomes

❯ Need for Repeatable and Safe Training

Hindalco needed a risk-free yet realistic training method to train new employees and upskill existing workers, without disrupting operations or compromising safety.

Our Approach

❯ Developed a Step-by-Step VR Simulation

We created a high-fidelity Virtual Reality training module focused on the Anode Change Process under Pot Processes. The training simulation allowed workers to:

• ☑️ Practice every step virtually, from preparation to completion
• ☑️ Interact with digital equipment mirroring real-world tools
• ☑️ Receive real-time guidance and error correction

❯ Immersive and Repeatable Learning Environment

The Anode Change Process is both complex and hazardous, involving heavy equipment, electrical hazards, and precise sequencing. Traditional training methods were:

• ☑️ Risk-free repetition of complex steps
• ☑️ Muscle memory building through hands-on experience
• ☑️ Immediate feedback to reinforce learning

The Result

❯ Tangible Benefits Observed:

• ✅ 100% reduction in training-related safety incidents
• ✅ 30% faster onboarding time for new plant operators
• ✅ Improved retention of SOPs and safety procedures
• ✅ Increased confidence among trainees before entering the real plant

Why It Matters

This case study reflects a larger shift in how heavy industries are rethinking safety training. By integrating VR-based skill training, companies like Hindalco are minimizing human risk, maximizing knowledge retention, and aligning with future-ready training methodologies. The solution is scalable across plants and applicable to multiple high-risk processes.

Ready to modernize your workforce training?

Talk to our team to explore how KOMPANIONS’ VR safety modules can reduce risk and improve performance at your plant.