Rubber & Tyre Machinery World

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Machinery Is The Key To Rubber Processing – Dr. Chakravarty

Machinery is the key to rubber processing and brought significant changes in rubber industry, says Dr. S.N.Chakravarty in an exclusive interview with Rubber Machinery World. Celebrating his 50th year in Rubber Industry working in different countries including India, he shares his experience.

Know A Rubber Leader

Dr. Chakravarty has many achievements to his credit. After working in Bayer AG, Germany for many years he became Technical Manager of Bayer (India) Ltd. and then of Modi Rubber Ltd. Subsequently he started his own Consultancy Organisation in Rubber and related field.

He is the past Chairman of Indian Rubber Institute and Rubber Committee (PCD14) of Bureau of Indian Standard (BIS), Fellow of Plastics & Rubber Institute, PRI (UK), Indian Rubber Institute (IRI),  Indian Chemical Society (ICS), Indian Institute of Chemical Engineers (IIChE), Inst. of Chemist and Member of Rubber Division, American Chemical Society (USA). He represented India in TC 45 / ISO & was a member of IRCO, UK Committee, Convenor of 1st Int. Rubber Conf., Rubber Con ’93 Delhi in 1993 and member of ITTAC for many years.

Dr. Chakravarty has been Hon. Professor of Indian Institute of Technology, Delhi and Kharagpur, visiting Faculty to different Universities & Institutes. He was the first President of Asian Rubber Forum to which all Asian countries like Japan, Korea, China, India, Malaysia, Sri Lanka, Nepal etc. are members.

Dr Chakravarty has more than 106 Publications in National & International journals of repute. His work in the area of Rubber Chemistry & Technology and educational activity are well recognised all over the country & abroad. Dr. Chakravarty has traveled widely over the world and has command over different languages.

Recently he was awarded the “TRiLA Life Time Achievement Award, 2015” by Tyre Times at the recently concluded Tyre expo in Chennai.

So, now you would understand my predicament when I had to limit to 10 questions to capture his vast knowledge, leadership and expertise to feature him in your Know Your Rubber Leader Series!

Fortunately (for me), he also shares his expertise through articles on this portal. (Read his earlier posts – Mixing & Mix Design and Injection Moulding Of Rubber Product)

Below are some thoughtful snippets of his interview while you could read the complete interview by clicking on the image below.

Know A Rubber Leader - Dr.Chakravarty

Click on this image to read the complete interview

  1. Would you say that rubber processing has undergone change in the last 4.5 decades that you have been with rubber industry? What were the drivers for this change?

Surely, rubber processing has undergone substantial changes over the last about 5 decades, This is mainly due to availability of developed machinery – Mixer, Extruder, Calender, Presses etc., along with electronic / microprocessor controls, as well as development of rubber technology & ingredients used in compounding. Machinery is the key to rubber processing.

  1. What role has machinery played in this change?

Machinery played many fold role in rubber industry. These developments of machinery have made it possible to

  • Improve production output (impact on cost)
  • Superior dispersion & homogeneity – improvement in property level.
  • Lowering of wastage – impact on cost
  • Dimensional accuracy of components
  • Accuracy in working – improvement in quality
  • Effective Quality Control (QC)
  • Energy saving – very important factor
  • Pollution Control, better housekeeping, health factor for the working people in this industry.


Read Complete Interview or Download PDF Here

I hope you find this interview insightful. Let me know your thoughts.

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Tire Production Simplified In A Flow Chart

My earlier post on Tyre Building Machine – 5 Amazing Videos You Must See was well received by the readers and they found it informative.

I have in earlier posts covered rubber machinery like Bale Cutter, Mixer, Mixing Mill, Batch-Off, Extruder, Tire Buffer, etc. However, its intriguing to see where all these equipment (along with the other machinery) goes into tire production.

This flow chart simplifies tire production overview and helps you visualize the various equipment that we discuss on this portal Rubber Machinery World in the right perspective.


The source of above flow chart is from Nell Achieve Website.

And just in case, you thought even for a microsecond ‘Is this all to tyre manufacturing?’, I correct you here.

The tire production process is a very meticulous and complex  affair. Click here to download the infographic from Giti that explains their tire production concisely.

I hope you found this post informative. Let me know.

If you liked this article, please do not forget to share with your colleagues, customers and friends. And If you would like to be informed of our articles regularly, please register with us for free updates today.


How To Select Your Rubber And Tyre Machinery? Insightful Advices From 6 CEO’s

“How To Select Your Rubber And Tyre Machinery?”

This subject question could have volumes written in theory. But today we focus on what the CEO’s advise, distilled down from their experience, expertise, and wisdom.

Your equipment supplier ecosystem includes New Manufacturers, Rebuilders, OEM Suppliers, Pre-Owned Machinery Suppliers and Agent representatives.

So I asked all the CEO’s the same question to give you a true perspective.

“What would you advice on machinery selection to buyers and users of rubber and tire equipment?”

The different views they offered here are not only insightful, they are pertinent, prudent and practical.

Read on in our Special Supplement here….

This special supplement is one of our efforts to give you useful knowledge on-the-go in a concise and timely manner. This topic based micro-editions is in addition to our other initiatives like ‘Know Your Supplier’ that provides you information on the machinery supplier ecosystem.

Watch Video Version of this supplement on YouTube or Download Full PDF Here.

If you liked this post, please share with your customers, colleagues and friends. And If you would like to be informed of our posts regularly, please register with us for free updates today.

If you are an equipment supplier and would like your organization to be promoted on Rubber Machinery World, please see the opportunities on Partner Me or Contact Me at for your customized offering.

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Practical Solutions On Equipment Simplified – A Know Your Supplier Special

At Rubber Machinery World, we understand your information requirements. Our effort on this portal to share authentic information to help you source your machinery wisely remains incomplete without notes on equipment suppliers from whom you source your rubber and tire equipment.

Hence, ‘Know Your Supplierseries is one of our advertorial initiatives to bring to you information on the machinery supplier ecosystem – Manufacturers, OEM Suppliers, Machine Rebuilders, Used and Pre-Owned Equipment Buyers & Suppliers, and Agents.

In Know Your Supplier editions, we cover an equipment supplier’s Competency, Capacity, Commitment, Culture, Communication, Market Presence, Technology, Solutions, amongst other details that you seek; so you know these organizations better and reach them quicker.

In this post, I introduce you to an equipment supplier based in India but wired globally. Read on to know why.

Pracsol Chemicals & Machinery is into trading of Machinery, Raw Materials and Chemicals since 2007 and is growing in reputation in machinery business. We understand from our conversation with Harish Nene, Chief Executive, that in the last 4 years they have secured landmark orders for Used Machinery from Indian Rubber and Tyre industry.

Pracsol is now fast building on this rising confidence and customer trust to extend practical equipment solutions to the industry in new machinery as well.

Flip through this Special Edition using the link –

In this conversation, Harish Nene outlines on a wide array of his business aspects right from the genesis of his company name to his experiences in rubber and tyre industry, partnership with JM Machinery USA, recent successes and new products on the anvil. Harish also informs us the unique service proposition Pracsol offers to their customers, their competence and comprehensive range of machinery offered to buyers.

I reproduce for you a few snapshots of our conversation here. (For full story, please do read and download here, this special edition of Know Your Supplier)

  • Pracsol is a strange name. What is the story behind this name?

Pracsol is derived from the words ‘Practical Solutions’. Through my experience of last 20 years in International Business, I would state that solution for a problem is possible if looked at it practically not by just following procedures.

Pracsol Logo

  • Having started in 2007 how has been your experience so far in this industry?

Business Ethics, Honesty, Transparency and Hard work is important. Customers who do business with me recognize that they can expect these from me and have helped me succeed in the rubber and tyre industry. I also have good support from my principal company. This makes things simple and gives me time to focus on delivering value to customers. From my last 7 years experience, I would opine that doing business with Private Companies is easier than doing business with Public Limited Companies.

  • Purchasing machinery is a major investment for most buyers and they would need technical inputs and customization. What level of pre-sales support do you offer?

We provide all the important technical details about the machinery with photographs. Through JM Machinery, we can aid in design and engineering from concept thru completion of the desired machine. If the customer insists on Physical Verification Report then physical verification is carried out by our principals’ engineers and a report is provided. The client has the liberty to visit for physical verification if the machines are available at our warehouse in USA.

  • Are you launching any new products?

We are targeting the rubber industry in Europe & USA to export our range of new machinery from India. We have recently bagged an order to design, manufacture and supply a NEW BATCH OFF for Europe. This is expected to be despatched by end of September 2015.


For full conversation and other details of Pracsol, access this special edition of Know Your Supplier in PDF here.

Meanwhile, here is a quick overview of industries covered by Pracsol and Harish Nene’s contacts if you would like to reach him quickly.


Know Your Supplier is an advertorial initiative of Rubber Machinery World and all information are as provided by the supplier. If you desire to know more, kindly reach out on the contact details provided or write to me stating the additional details you seek on this supplier.

And if you would like your organization to be promoted on Rubber Machinery World, please see the opportunities on Partner Me or Contact Me at for your customized offering.


Editor’s Pick: Injection Moulding Of Rubber Product (Part 2)

Continuing with Part 1 of this article, by Dr.S.N.Chakravarty, President – Elastomer Technology Development Society and Ex-Chairman, Indian Rubber Institute (IRI).

Now, let us look  more deeply into Injection moulding process.

Types of Injection Moulding Machines

The following distinctions may be made between the machines used:

  • The toggle or hydraulic mould closing mechanism
  • The plunger or screw type plasticating and injection unit
  • The plunger screw type plastication unit may be further subdivided into those with and those without reciprocating movement.

The fully hydraulic mould clamping mechanism is preferred today.

Desma Injection Moulding Machine

Image: Desma

Operation Principles: Three types of injection moulding operations can be distinguished according to the differences in tool design and process sequence:

  • The conventional
  • The injection forming and
  • The transfer-injection moulding methods

The essential advantage of screw plasticating machines is the very short cycle time which is very important for high volume production, e.g. using rotary table mould arrangements.

One of the requirements for automated rubber injection moulding is to produce a rubber compound of the highest possible uniformity, which is still quite a difficult task even today.

Other important factors depending on controlled mixing are those of optimum and uniform reheological properties, the dispersion of the ingredients  in the compounds, and computer-aided optimization of the vulcanization process, especially for thick-walled moulding. Compounds with consistent processing properties can now be produced using automatically controlled internal mixers.

Another problem is that of automatically feeding the raw material into the injection moulding machine. The strip feeding method in its original form is too imprecise and needs constant manual attention. Recently, however, the strip feeding method has been refined by using strips of precise dimensions wound on drums, allowing limited periods of automated production. Another method used is to feed the compound into the injection moulding machine in granulated form. This may prove to be the best method for fully automated production in the future.

The manufacturer who has installed injection moulding equipment (or who is considering so doing) must consider four general questions:

  • What rubber to use ?
  • How to adjust machine controls ?
  • Which formulations ?
  • What end properties to expect ?

Injection moulding is specially suitable for the mass production of high quality precision components.

For a given barrel temperature, the higher the heat build-up the shorter the cure time. Alternatively, for a fixed injection temperature, the higher the heat build-up the lower the temperature at which the barrel of the machine may be set thus minimizing the danger of premature vulcanization (scorch) in the barrel.

Injection moulding process for elastomeric compound have certain specific advantages over the moulding process.

In Compression and Transfer moulding,  elastomer is pushed into the mould cavity gradually as the mould closes.  Therefore  in the process, though the elastomer gets in contact with the hot surface of the mould , it is not subjected to any pressure, which is  created when the mould is at closing face.  For vulcanization, both temperature & pressure are required.

In injection moulding, mould first closes fully and elastomer is pushed into the mould with high speed.  The cavity of the mould is very quickly filled and a pressure is developed within a very short time, thereby, triggering the process of vulcanization.

In compression moulding process or in transfer moulding process, the flow of material stops immediately when the mould is completely closed. Therefore, typical problems like generation of small gases and vapour, shrinkage of elastomer after vulcanization cannot really be rectified in the above process.

In injection moulding machine there is always a special feature which is known as Post Injection Pressure. Even when the cavity is completely filled and the process of vulcanization has started, the injection unit still continue to push in the elastomer compound for a reasonable length of time ensuring completely porosity free moulding.

REP Injection Moulding Machine

Video of Compact Multisation Molding Machine. Image – REP

Advantages of Injection Moulding

  • Allow automation to be introduced into the moulding operation.
  • Simplifies preparation of rubber: cutting, shaping and weighing of blanks eliminated.
  • Cure times reduced to one-tenth or less compared with compression moulding
  • Materials, trimming and inspection costs reduced.
  • Product quality improved: better dimensional control and more uniform physical properties.

Cure time is considered as a measure of productivity obtainable. This is the time elapsed between injection and opening the mould. For a given set of operating conditions, cure time depends on the thickness of the product.

Early work showed that barrel temperature was one of the most important factors affecting injection temperature.

As Screw speed increases, rubber in the barrel of the injection machine becomes hotter and it is possible to obtain higher injection temperatures and shorter cure times. Cure time, assessed by the hardness of the top, center and bottom of the moulding, closely follows the injection temperature and illustrates that under the prevailing back pressure and barrel temperature conditions there is an optimum screw speed.

Injection temperature increases with elevation of barrel temperature. When there is no screw delay in operation, temperatures above optimum level causes premature vulcanization of rubber in the barrel.

Screw-back pressure is the adjustable hydraulic pressure which acts to pressurize the plasticized rubber in the injection chamber during screw rotation. Injection temperature increases with screw-back pressure.

As the Nozzle orifice diameter is reduced, the injection temperature rises but, below a diameter of 2mm (0.075 in), it levels off .

With a relatively wide nozzle orifice (3.2mm; 0.125 in), an increase in the injection pressure gives a steady rise in injection temperature and a useful reduction in injection time.

Machine manufacturers advise use of 80-90 percent of the maximum available pressure to save wear and tear on the machine.


The principles of successful compounding for injection moulding follow the normal rules. The choice of curing system determines properties such as scorch rate, cure rate, reversion resistance, modulus, strength, resilience and ageing resistance. Control of mix viscosity can be used with caution to optimize mould filling time and hence cure time. Required stiffness, strength and cost can be obtained by selection of filler at an appropriate volume loading.

Physical properties (tensile strength, modulus, etc.) of injection moulded components can be expected to be very similar to those made by compression moulding although the modulus of injection moulded samples may be equal to  that of compression moulded samples, the tensile strength tends to be higher. There is also published evidence that injection moulded components are similar to or better than compression moulded ones in respect of elongation at break, tear strength, hardness, resilience and oven ageing resistance. There have also been claims that in some circumstances certain properties (e.g. Dynamic properties ) of injection moulded products are superior.

Particular interest attaches to the injection moulding of thick  components such as engine mounting and shock absorbers – traditional high-quality natural rubber products.  The greatest benefits of injection moulding are obtained when moulding thick sections since injection at  high temperature saves the time required to heat rubber by the relatively slow transfer of heat into a mix of poor thermal conductivity.

Compound with higher Rubber Hydrocarbon content (RHC) is preferable for injection moulding process.

Advantages and Disadvantages of Injection Moulding Process

A comparison of injection moulding with compression moulding shows the following advantages and disadvantages:

Advantages are for example:

  • Reduced preparatory labour
  • Transport and storing of the cut reforms is eliminated.
  • Considerably shorter vulcanization times because of homogeneously preheated material.
  • More homogeneous degree of vulcanisaiton of the finished part at high injection temperature.
  • No bumping.
  • Faster removal of the finished parts
  • Simplification of de-flashing
  • Lowering of the waste and scrap rate
  • Possibility of automation

These advantages are contrasted by the disadvantages of considerably higher investment costs for moulds and machinery. The injection moulding process can not also handle as high volumes as compression moulding.

Economic Efficiency

Which method is most economical for the production of moulded parts, compression moulding with low investment costs but with higher production costs or injection moulding with higher investment costs, depends to a high degree on the number of parts to be produced. Below certain limits it is advantageous to work with low investments but higher wave costs while for high volume production runs  higher investments may be preferable.

However, considering improvement in product quality leading to higher performance  and longer life made by injection moulding process, it is preferable to go for the same.

Taking into account of all factors associated with injection moulding, namely – Capital Investment, higher precision of working, higher (improved) compound cost, Qualified & experienced Technologist needed etc. would lead to a higher cost of the finished product.

Besides choice of Machine & Process one has to keep in mind that performance of a rubber product depends on many other factors which need equal attention. These are, for example, for certain metal to rubber bonded items used by Indian Railway.

  1. Application condition
  2. Environmental condition – Oxygen, Ozone, Fatigue, Displacement Amplitude etc.
  3. Compression under continuous load
  4. Geometry / design of the product – FEA Analysis results


Simultaneously to consider which aspects can improve product performance.  For example,

Compound Quality – Homogeneous Mixing / Mix quality (Kneader is not a suitable substitute of internal mixer)

Rheometer provides cure characteristics information but does not indicate mixing quality .

Homogeneity of the compound sheet

Lower Heat Built-up (Resilience /Hysteresis)

Ageing resistance over longer period

Summarizing, it is quite clear that only particular machine or process usage will not lead to improved product performance but combination of all related points development is essential to achieve the desired goal. Any specification should be drawn only after ascertaining the results of these studies.


  1. Injection moulding of natural rubber – MRPRA Booklet
  2. Rubber Technology Handbook – W. Hofmann
  3. A.I. Isayev  & M. Wan – Rubber Chemistry & Technol. 69, No. 2, p. 277, & 294, 1996
  4. K. Yakemoto, T. Shiroganeya, H. ITO & T. Sakai. International Conference on Rubber, Calcutta, Dec. 12 -14, 1997, p.73

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Editor’s Pick: Injection Moulding Of Rubber Product (Part 1)

Here is an informative piece on injection moulding of rubber products. This article is sent to me by Dr.S.N.Chakravarty, President – Elastomer Technology Development Society and Ex-Chairman, Indian Rubber Institute (IRI).

Moulded rubber products, including rubber to metal bonded items, are manufactured by following process world-wide. Choice of process depends on different factors like Product Geometry, Type of Polymer, Volume, Cost Vs Market Price realization, Manpower & Space etc.

  1. Compression Moulding
  2. Transfer Moulding
  3. Injection Moulding

All the process are well established and widely used. Each process has certain advantages & disadvantages. To get optimum result, you all need suitably developed compound & manpower besides right machine & process.

Compound is developed to meet requirement of laid down specification including special requirement (e.g. dynamic fatigue, heat development, tear resistance, load deflection, etc.) and retention of properties on ageing for specific period at elevated temperature. The later indicates approximate idea for product performance & life. All these obviously have bearing on cost factor.

For different moulding process three major properties or compound behavior is to be considered – Compound Flow Characteristics, Mooney Viscosity and Scorch Characteristics. Each process calls for adjustment of these parameters for suitable working.


Primary purpose of moulding is to provide shape & size of the product. Porosity & Knit in the product are to be avoided. Porosity is caused by moisture in the compound & moulding pressure and Knit by improper compound flow.

In case of Compression moulding, preparation of Blank (shape, size, weight) plays important role to control mould flow / avoid air entrapment and excess flash.

Compression Moulding Schematic -

Compression Moulding – (Left) Open mould With elastomer blank placed in the cavity; and (Right) Mould closed forming the finished product profile. Image: JW Elastomer Engg Guide

This point is not necessary for Transfer or Injection moulding where feeding system & wastage of semi-scorched compound are more important factor.

Transfer Moulding

Transfer Moulding – (Left) Open mould With elastomer blank placed in the transfer pot; and (Right) Mould shut with elastomer injected into the cavity. Image: JW Elastomer Engg Guide

Basics of Injection Moulding

Injection Moulding is an important processing technique for converting elastomeric materials into final products. The injection moulding machine automatically performs: raw material feeding, heating, polymer mix plasticization, and mould injection; all operations are performed under controllable conditions of temperature, time, speed, and pressure.

Some peculiar problems arising during injection moulding are associated with the drastic change in rubber compound rheological properties which occur upon vulcanization. In particular, during the filling stage, the rubber compound in the mould-filling process. This is a phenomenon that may lead to the loss of processability of the rubber compound and incomplete mould filling.

Rubber compound or thermosets go through an irreversible chemical change during the forming process. Thus, the critical issue in modeling the injection moulding process for such polymeric materials, is developing a viscosity model that can accurately describe the reheological and chemo-rheological behavior.

As Injection Moulding of Rubber compounds becomes an increasingly important moulding process, an understanding of the nature of coupling the rheological behavior with cure kinetics of rubber compounds and the process itself becomes paramount. Effective control of product quality, as well as the ability to optimize moulding conditions, will depend on a further development of such an understanding.

During Injection Moulding, the Rubber compounds are subjected to high shear rates and as a result experience a thermal history leading to chemical reaction (cross linking). It is recognized that the processibility of a rubber compound is predominantly determined by its viscosity which is balanced by tow effects: the drastic decrease in viscosity with increasing shear rate: and a significant increase in viscosity following the onset of vulcanization. Thus, different rubber compounds not only display different rheological properties, by also possess different chemo-rheological behavior.

Injection Moulding

Injection Moulding. Image: JW Elastomer Engg Guide

It is seen that an increase in the inlet temperature does not significantly reduce the cycle time needed to reach a specified cure level. One cannot further raise the inlet temperature to achieve a shorter cycle time due to the possibility of curing in the barrel. Therefore, the distribution of state-of cure in the moulded rubber articles is strongly dependent upon the mould temperature and less dependent upon the inlet temperature.

It is interesting to know how the injection speeds affects the state-of-cure achieved during the same mould cycle duration. For this purpose experiments were conducted in which the injection speed was set  at a definite speed. At this injection speed the calculation shows that there is no cure during the filling stage.

A comparison is made between the predicted and measured gap-wise distribution of state-of-cure in mouldings obtained where cure occurs during filling by  lower injection speed, and where it does not occur during filling at higher injection speed. In the later case, the ultimate state-of-cure achieved in the cure stage is the overall state-of-cure achieved during entire moulding cycle.

In the case when cure occurs during filling, the overall state –of-cure for the entire moulding cycle is the state-of-cure at the end of filling plus the state-of-cure further developed during the cure. Surprisingly, both experimental and predicted gap-wise results show that a higher stat-of-cure is obtained at higher injection speed for the same moulding cycle.

This can be explained by the fact that the rubber material gets into the cavity much faster and therefore has a much longer time to cure in the cavity.

The development of the state-of-cure in the post-filling stage indicated that the mould temperature and injection speed strongly affected the evaluation of state-of-cure within the moulded parts. The effects of the inlet temperature on the state-of-cure was found to be insignificant.

With the increasing demands for high quality and productivity in injection moulding, it has become more important to keep consistently constant dimensional precision. Various properties of polymer such as melt fluidity and density are dependent highly upon temperature. Therefore the consistency in quality is primarily dominated by the temperature variations of mould wall and / or polymer in the barrel.

Fluctuations of these temperatures, however, are indispensable to some extent, due to the heat exchange among polymer, mould, machine and environment, and transient temperature change at the start-up, etc. An adaptive holding pressure control system was developed to get constants product weight by changing holding pressure adapted to the temperature variations.

In Part 2, you will look more deeply into Injection moulding process.

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The Ultimate Guide to Asset Management

If you had read my earlier post “A New Hope: Top 6 Things I Learnt At NRC 2015 Mumbai“, then you would have also read my learning from Naushad Shikalgar of J.N.Engineering – ‘Proactive Machinery Maintenance is not an expense and is an investment that has long-term benefits’.

Maintenance is important in any organization. Without proper maintenance, assets deteriorate over time reducing the quality of your output produced. It can also impact the safety of your asset or your people who operate it.

Traditionally, maintenance has been viewed as a cost center in an organization because it costs you money to hire maintenance technicians and purchase the spare parts to keep your systems running smoothly. Too often, senior executives ignore the value-add that maintenance can bring to your organization. These include:

  • A reduction in reactive maintenance costs
  • Reducing costs to restart production after a breakdown
  • Limiting production scrap
  • Costs of downtime such as missed orders and lost revenue
  • Customer perception/satisfaction
  • Improved quality of products
  • Reduced environmental impact


By definition, Asset management is a systematic process of deploying, operating, maintaining, upgrading, and disposing of assets cost-effectively.

During his talk, Naushad spoke extensively on Asset Management Strategy-Plan-Execution including the various approaches to maintenance that I found interesting and hope you too would like it when you read. Hence, I have reproduced the 34 slides (click on the picture below) here that effectively forms a comprehensive guide on asset management.

Asset Management

Click on Image

Summarizing, asset management focuses on assuring your people, parts and processes are optimized to improve asset performance. Reducing inventory, maintenance costs and the number of downtime events raises your productivity, while simultaneously driving financial performance and predictability. It also helps your employees with the right tools to make good decisions about driving your plant performance.

Do you agree? How do you look at Asset Management?

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