Simulation of a Tyre Factory for a Leading Producer – Conveyer System
Simulation of a Tyre Factory for a Leading Producer – Plant Simulation
February 13, 2023
Simulation of a Tyre Factory for a Leading Producer – New Plant
March 1, 2023One of India’s leading tyre manufacturers planned to install a conveyor system to replace manual trolleys that carried tyres through Tyre Building Machines (TBM), Curing Machines (TCMs) and Inspection stations.
Key Points
- Tyre Industry
- AutoMod
- Bottleneck Analysis
- Feasibility Study
- Buffer Analysis
Client's Challenge
- Check feasibility and validate the proposal
- Identify and alleviate bottlenecks in the system
- Recommend alternatives design proposals if required
PMI's Approach
We carried out static analysis and 3D simulation to study in detail:
- TBM à TCM Sub-system with overhead conveyors measuring 600 meters in length
- TCM à Inspection Sub-system with similar features
Findings & Recommendations
We were able to identify that the client’s proposal would meet only about 30 % of their monthly target due to:
- Insufficient number of empty hangers available at tyre building machines, reducing tyre supply into the system
- Mismatch in production and consumption at TBMs and TCMs
After experimenting with several what-if scenarios, we recommended the following changes to achieve their target
- A hybrid centralized buffer system of 3000 tyre capacity with defined rules for operation
- Minimum buffer to be used near tyre curing machines and inspection
- Optimum hanger speed and number of carriers to be used in the system
