Hindalco — uniform PPE compliance across three shifts and rotating contractors.

The third shift was always the safety gap.

Hindalco's mining and metals operations run 24-hour shifts with contractor workforces that change every quarter. Maintaining consistent safety compliance — PPE, no-go zones, proximity alerts near heavy machinery — across this workforce variability was the biggest challenge. The third shift, when inspection rounds were least frequent and contractor familiarity with site rules was lowest, had measurably higher safety incident rates than day operations.

Conventional response — more training, more supervisors, more posters — produced marginal improvement. The structural reality remained: a finite supervisor pool could not be present at every safety-relevant location, every shift, with consistent enforcement. The supervisor model could not scale to the safety standard required.

• Third shift safety compliance measurably lower than day operations
• Contractor workforce changes quarterly — training continuity difficult
• Heavy equipment proximity events occur unpredictably across all shifts
• Manual supervision cannot cover every location every shift
• PPE compliance variability creates audit risk and incident exposure

Make safety a system property, not a supervisory task.

Cognecto deployed Photon across Hindalco's existing CCTV infrastructure — covering every PPE access point, every no-go zone, every heavy machinery proximity area. The system runs continuously — with no shift-based fatigue, no contractor unfamiliarity, no third-shift attention drop. Every safety event is captured, classified, and stored as an immutable record that satisfies every DGMS compliance requirement.

"We didn't change our workforce. We changed what was watching."

PPE compliance at Hindalco is now uniform at 97% across all three shifts — including the third shift that historically had the largest compliance gap. The mechanism for achieving this was structural rather than behavioural: a continuous Vision AI watch replaced intermittent manual supervision. Same workforce, same training, completely different outcome.