There are lots of repetitive manual measurementsMeasurements in the production control of aluminum reduction cellsAluminum reduction cells. The pot controller takes the entire pot as a single ‘point’ by analyzing the cell voltageVoltage and current for control purposes. As the size of the reduction cellsReduction cell continues to increase, issues such as uneven anodeAnode-cathode distance distributionDistribution, uneven aluminaAlumina distributionDistribution, and uneven heat distributionDistribution have become more prominent, severely limiting the improvement of the intelligence and digitalizationDigitalization levels in ChinaChina’s aluminum productionAluminum production control. This paper presents the development of a ‘Digital MonitoringParameters digital monitoring and Intelligent ControlIntelligent control System’ (DM&IC), which expands the online monitoringOnline monitoring parameters from traditional pot voltageVoltage and current to 65 new digital parameters, including pot voltageVoltage, pot current, anode currentAnode current distributionCurrent distribution, bath temperature, metalMetals level, bath level and 12 cathode voltage dropsVoltage drop. The accuracy of these parameters is sufficient to meet the needs of daily operation and control. The data from these automatically measured parameters were thoroughly analyzed and applied for new intelligent controlIntelligent control methods, including regional alumina controlRegional alumina control, anode effect detection and terminationAnode effect detection and termination, and predictions of set voltageVoltage, Al2O3 feeding, AlF3 additions and metalMetals tap weight. A six-month industrial trial was then conducted to evaluate the system’s performance.