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Here’s How Siemens Technology Drives The Tyre Industry

Tyre manufacturing is a highly competitive field and faces volatile changes. The ecosystem of tyre manufacturers, raw material suppliers, and machinery manufacturers are affected by industry consolidation, innovations in technology, labeling and safety requirements, increasing government regulations, shifting customer demands, and the pressure for lower customer prices.

Tyre manufacturing is also a complex process. A fault or improper procedure at any of the manufacturing stages threatens the structural integrity of the tire. And, tyre manufacturers demand the highest productivity from every stage of their manufacturing process.

This means every tyre machinery manufacturer must produce machines that offer high production output, manufacturing accuracy, reliability and product quality with low processing and maintenance costs and lowest possible manpower.

It is here Siemens, the automation and drive solutions leader, brings in technology that drives the tyre industry. Using cutting-edge technology such as Totally Integrated Automation from Siemens, local tyre manufacturers are able to fulfill demand for new and retrofit solutions, in the process sustaining their profitable business.

TIA for the Tyre Industry

The tyre industry in India stands to gain massively by integrating automation right at the onset of the tyre production life-cycle. The typical value chain for manufacturing tyres start from R&D, moving to production planning, production of tyres, quality assurance, warehousing and supply.

Under the motto “Get your tire production rolling”, Siemens successfully participated in the leading international Tyre Technology Expo 2016 in Hannover on February 16 to 18, 2016. At the so far largest show – which was 20 % bigger than in 2015Siemens held highly interesting customer discussions both with various tyre manufacturers and machine OEMs.

Siemens at TTE2016

Siemens Stall at TTE2016

Their discussions were supported by the highlights and demonstrations shown by the booth personnel as well as the Siemens presentations held at the conference. This exhibition provided a perfect platform for Siemens to showcase its latest technologies for the tyre manufacturing industries from across the world.

Through the Totally Integrated Automation and Siemens PLM software (which has a significant presence in India), Indian tyre manufacturers have ready access to technology for data integration between the various points of the value chain.

The innovative engineering framework TIA Portal integrates HMI, controllers, distributed IO, motion control and drives seamlessly into one engineering environment.

In addition, by implementing the SIMATIC range of solutions, machine builders for the tyre industry can increase productivity and cost efficiency through the latest technology.

Siemens S7 1500 PLC

SIMATIC PLCs support tyre manufacturers right from factory layouts and factory designs that are highly automated according to their requirements.

Explains Siemens official, “SIMATIC S7-1500 has proven to have the highest efficiency and maximum usability for complex automation tasks, having set new standards in system performance, usability, quality of control and response times. The SIMATIC S7-1200 Basic Controllers are the ideal choice for simple and autonomous tasks in the low to mid performance ranges.

What do you think?


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Industrie 4.0 And Why You Should Be Excited About It?

If you are even remotely following the advancements in manufacturing and automation, then you have already heard this term – Industrie 4.0. A German branded initiative, this is a term coined for the next stage of manufacturing that describes the main future development tasks required to achieve a ‘Smart Factory‘.

To quickly understand, you may visualize smart factories as ‘social networks’ where humans, machines and materials communicate and interact in real time.

Considered the 4th industrial revolution in manufacturing (watch a video), Industrie 4.0 is a dynamic process of evolution. It refers to the technological evolution from embedded systems to Cyber-Physical Systems (CPS).

Too much of jargons? Let me make an effort to explain…..

Relevance of CPS

In your manufacturing environment, these Cyber-Physical Systems comprise of smart machines, storage systems and production facilities capable of autonomously exchanging information, triggering actions and controlling each other independently.

This means all your machines, processes, control systems, logistics and even end-products are closely interconnected via internet-based, data-handling technologies and devices.

CPS makes your next level of decentralization realistic. It improves your resource productivity and efficiency, enables more flexible models of your work organization.

Says, Ashutosh Chincholikar, Business Head, Smart Controls India Ltd, “With Industrie 4.0, rubber and tyre machinery will no longer simply ‘processes’ the product, but your product would communicate with the machinery to tell it exactly what to do.”

Industrie-4.0-Rubber-Tyre-Machinery

Benefits of Industrie 4.0

Your benefits include flexibility in specification and volume, fine-tuning to your customer needs, and improving efficiency as a way to reduce your cost.

Your product development-to-market and order-to-shipment lead times become shorter. Expensive downtime for your machinery and plant gets reduced through remote monitoring and predictive maintenance.

Digitization, connected-ness and virtual tool planning opens your door to customized mass-production. This means you can produce very small batch sizes and yet sell at a profit.  Flexible manufacturing may mean that more of your parts and production materials have to be detected, inspected and identified. Transparency and reproducibility of your processes will enhance your product quality.

Experiences shared by Smart Controls India Ltd, include significant benefits like

  • 5% increase in productivity on 20 machines was equal to an extra machine.
  • 25% saving on a plant in Auto industry
  • 11% efficiency improvements in first 3 months at a Tire Company.
  • 68% gain in production by just fine tuning setup processes (up from 410 to 690 parts/week)
  • A large equipment manufacturer’s OEE shot up from 24% to 62% on machines

It is these benefits of speed, flexibility, quality amongst others that should keep you excited and upbeat about the prospects of Industrie 4.0. Further when you use CPS, you will have a clear advantage to attract the best employee talent since you can offer a better work-life balance.

| It is these benefits of speed, flexibility, quality amongst others that should keep you excited and upbeat about the prospects of Industrie 4.0. |

Need for a balanced approach

Interestingly, Industrie 4.0 goes by a variety of names: ‘Advanced Manufacturing’ in the USA and the UK, ‘les usines du futur’ (The Factories of the Future) in France, ‘Made Different – Factories of the Future’ in Belgium, and “Smart Industries” in the Netherlands.

As a manufacturer, you definitely need to procure equipment with right level of futuristic automation. Because Industrie 4.0 is bringing fundamental change to your business competition in today’s ‘VUCA’ (Volatile, Uncertain, Complex and Ambiguous) world.  If you continue using today’s automation systems you will fail due to excess cost in automation.

| If you continue using today’s automation systems you will fail due to excess cost in automation. |

However, it is also necessary to find the balance between full automation and manual work. It doesn’t make sense to automate all your manufacturing processes completely as the cost of that will be too high.

For example, tire production is high-volume customization. The tire industry seeks to consistently improve quality while cutting waste, thus reduce the cost of each tire. Experts and Leaders will tell you that the steps you need to do this in China or India are different than they are in Japan or in Europe or in the U.S.

Every application must be evaluated with regards to the breakeven point. And that is where you will benefit with the assistance of a systems integrator.

balanced-approach

Adopt a Balanced Approach. (Image Source: Web)

| Every application must be evaluated with regards to the break-even point.|

Adds Ashutosh, “In order to implement automation solutions in the tyre industry someone who understands the intricacies of tyre manufacturing processes – from mixing, tyre building, curing to inspection – is needed. This is where Smart Controls plays a big role. With over 15 years of experience in serving the tyre industry, Smart Controls has full knowledge and experience of using the Siemens Technological Platform to implement automation solutions for almost all processes of tyre making.”

(You may wish to hear more on the ‘role of a system integrator in your smart factory’, when Ashutosh Chincholikar speaks at the International Rubber Conference in Chennai on March 1-3, 2016.) 

Summarizing, Industrie 4.0 is more than just a buzzword today and hence important that you take notice. Because it ensures that your resources are used more efficiently while people and machinery work far more productively.

Let us know your thoughts on Smart Factory and and plans for Industrie 4.0.


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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.


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