Tata Steel is expanding the use of artificial intelligence, connected workforce systems and remote operations across its operations as it seeks to strengthen workplace safety and prevent accidents in real time.
The steelmaker is using more than 10,000 CCTV cameras along with AI-enabled surveillance to identify unsafe behaviour and trigger alerts for supervisors. The approach is aimed at moving beyond post-incident investigation towards early detection and intervention.
The company is also deploying its Connected Workforce platform across its operations. AI-enabled gate passes and beacons installed within plants track employee movement and flag deviations, helping ensure workers enter only authorised areas.
Tata Steel is expanding Integrated Remote Operation Centres (iRoCs), which allow hazardous activities in mines and plants to be monitored and, where possible, controlled remotely. These centres bring together CCTV feeds, plant and machinery data and other operational information, reducing workers’ exposure to hazardous environments while improving coordination during emergencies.
Remote operations could also support workforce attraction by reducing exposure to hot, humid and high-noise industrial environments.
AI is being extended to logistics safety, with driver-fatigue monitoring systems being used across trucks and trailers entering Tata Steel plants. Camera-based systems can identify signs of fatigue, head movement and mobile-phone use and trigger alerts. Technology is also being deployed to prevent vehicles from coming into contact with overhead cables.
The company’s digital safety systems include real-time hazard detection, IoT monitoring, predictive asset-health analysis, drones, smart surveillance and GenAI-enabled safety observations. Tata Steel expects AI-powered hazard prediction, computer vision, digital twins, autonomous inspections, wearables and connected-worker technologies to play a larger role in industrial safety by 2035.
The company has also expanded its safety agenda to cover mental health, heat stress, fatigue and ergonomics through a five-pillar wellness framework covering physical, emotional, occupational, social and financial wellbeing.
Tata Steel reported a 38 per cent reduction in its group-wide lost time injury frequency rate over the past 15 years. It spent Rs 802.17 crore on environment, safety and compliance projects in FY2025–26, compared with Rs 1,036.25 crore in the previous financial year.
