Overview
To facilitate the ever-increasing demand of the Indian market for quality Tires, Japanese multinational giant Bridgestone has set up its state-of-art manufacturing facilities in Chakan, Pune in 2013. In course of their search of new vendors for this 2nd plant in India, Automag has been selected as their “quality vendor” in 2013 for their TBR (Truck Bus Radial) Tire production. In Dec 2012, Automag achieved the milestone of entry to this Tire segment in big way by getting huge single order of “TBR tire curing & inspection line” from Bridgestone India. AUTOMAG successfully commissioned this project in June 2013 by winning “best supplier award” to become their first preferred choice in just one year.
In year 2014, AUTOMAG surpassed some more milestones by installing their 2nd Phase of PSR (Passenger car Radial) curing & inspection line where 1st phase was supplied by other Vendors from Pune region.
After the year 2014 till date, Automag successfully executed many new projects, replaced many other local vendors supplied equipment & also helped Bridgestone in localization of many imported equipment in their both Pune as well as Pithampur facilities.
Customer Profile
| Industry: | Auto ancillary (Tire Manufacturing) |
| Location: | Pune, India |
| Challenge: | Upgrading the Phase-2 of PSR inspection line Phase-2 to overcome many production, spare & maintenance issue to upgraded design to reduce inefficiencies. |
Problem Statement
The client was facing significant challenges with their existing phase-1 line with many design faults with roller jamming, traffic management faults, outdated rubber beltings with noise & repeated parts replacements. These challenges resulted in production loss, increased maintenance budget & spare management issue by end of service support of certain bought out items.
Key Metrics
- Production Efficiency
- Maintenance Time
- Improved maintenance friendly design
- Flexible & reliable BO maker selection
AUTOMAG's Solution
AUTOMAG implemented a state-of-the-art inspection line with its indigenous design with detailed analysis for maximum efficiency and adaptability. The solution included:
01.
Conveyor System
Custom-engineered to offer unparalleled flexibility, angular flow study in gravity flow to enhance tire movement. Also, proper sensor position study & implementation has assured smooth traffic at divergence / convergence.
02.
Stopper design
With seamless study on Tire jamming issue, stopper design has been updated with modified cylinder placement. This has reduced manual intervention during tire struck and overcome production loss.
03.
Belt material analysis
By real time study at line for noise & transfer friction of inclined belt, it has been replaced by PVC belting after various discussion with potential stakeholders. This activity not only reduced few decibels but also improved savings on yearly energy consumption with some reduction in motor ratings.
04.
Spare management
With suggestion of proper reliable bought out make for rollers, belt, pneumatics etc improved spare management enabling predictive maintenance and minimizing downtime.
Results
Increased Production Efficiency: Achieved increase in production efficiency, surpassing the initial goal ensuring superior product quality.
Reduced Operator Time: Turnaround time of operator due to tire jamming was reduced saving man hour cost.
Cost Savings: Effective cost saving in belt input cost, production cost due to improved efficiency and reduced energy consumption.
Conclusion
The implementation of AUTOMAG's expert design & quality manufacturing in new installation have transformed the client's manufacturing operations, setting a new standard for efficiency, flexibility, and sustainability in the Tire industry. The project not only met their expectations but also exceeded the initial goals, demonstrating AUTOMAG's commitment in delivering reliable products with customized innovative solutions to drive operational excellence.