Introduction
Modern tyre manufacturing is an intricate dance of machines, manpower, and movement. For one of India’s leading tyre producers, streamlining that movement became the next frontier of efficiency. The company planned to replace manual trolleys, which transported tyres between Tyre Building Machines (TBMs), Curing Machines (TCMs), and Inspection Stations, with a fully automated conveyor system. The expectation? A leaner, faster, and more synchronized production line.
But with over 600 meters of overhead conveyors planned and dozens of interdependent stations, the project’s complexity demanded a thorough evaluation before implementation. That’s where Production Modeling India (PMI) stepped in.
Client’s Challenge
• Feasibility check of the conveyor proposal across TBM, TCM, and inspection sub-systems
• Identification and resolution of system bottlenecks
• Recommendation of design alternatives to better meet demand
• Optimizing carrier availability, hanger speed, and buffer strategy
The shift from manual to automated transport would only be worthwhile if it boosted throughput and reduced inefficiencies, not if it replaced one bottleneck with another.
Boosting Plant Efficiency through Conveyor System Simulation: A Tyre Industry Case Study
PMI’s Simulation Strategy
PMI adopted a two-pronged approach combining static analysis with 3D simulation using AutoMod. The system was studied in two segments:
• TBM to TCM conveyor sub-system
• TCM to Inspection conveyor sub-system
Each component was modeled to reflect real-world processing times, loading rules, and carrier dynamics. The focus was on simulating tyre flow, assessing carrier return times, and evaluating system responsiveness under peak loads.
Key Findings & Recommendations
Initial simulations raised a red flag. The proposed system, as designed, could support only 30% of the required monthly production. The bottlenecks were subtle but significant:
• Insufficient availability of empty hangers at TBMs caused slow tyre inflow into the system
• Mismatch between TBM output and TCM input, leading to idle times and congestion
• Lack of effective buffer strategy, resulting in accumulation at critical junctions
To resolve these issues, PMI tested multiple scenarios and proposed the following improvements:
• Hybrid centralized buffer system with a capacity for 3,000 tyres, offering dynamic control and redistribution across stations.
• Defined buffer zones near TCMs and Inspection stations to absorb flow shocks and minimize delays.
• Optimal configuration of hanger speed and carrier count, ensuring a smooth, continuous loop without starvation or overloading.
Conclusion
The simulation didn’t just test feasibility—it refined the roadmap. With PMI’s insights, the client was able to align conveyor design with actual operational needs. The result? A more reliable, synchronized, and scalable conveyor system, paving the way for higher efficiency and future growth.
When it comes to automation, precision planning isn't optional—it’s transformational.