Aluminium of Greece enhances process optimization through real‑time monitoring of bauxite consumption. Managing multiple bauxite grades with varying chemical consistency is a key challenge for alumina refineries as it impacts alumina yield and process efficiency. An AI‑driven solution using smart cameras, GPS, IoT sensors, and computer‑vision algorithms was built to identify bauxite type, track dumping events, and integrate validated data into the AVEVA PI System for advanced analytics. The resulting visibility enables improved digestion control, reduced bauxite specific consumption, A/C ratio optimization, and establishes a foundation for future ML/APC applications.