Operating one of the world’s largest aluminium smelters in an industry marked by raw material and freight cost volatility, EGA undertook a 4IR transformation to further increase its cost-competitiveness, agility and flexibility, as well as enhance safety and sustainability. In three years, the site implemented over 80 use cases and upskilled over 20% of its workforce, injecting advanced AI into a traditional and labour-intense industry. The site used deep learning computer vision and LLM to optimize frontline operations, reducing operational downtimes by 50% and non-productive time by 18% – raising overall equipment effectiveness by 12%.