Summary
When one of India's leading Tyre makers launched an ambitious plant expansion to double the output, the task was not merely scaling up but scaling it efficiently. The company had made heavy investments in the latest automation, adding a new Automated Storage & Retrieval System (ASRS), conveyor networks, Electro Monorail System (EMS) loops, and gantry cranes. The aim was to optimize the material flow, minimize manual handling, and increase productivity.
But for this massive infrastructure transformation to produce desired results, it was necessary to confirm the general system design and performance in actual operational environments. That's where PMI came in.
Client's Objectives and Challenges
The main objective of the simulation study was to confirm the effectiveness of the new systems installed, such as EMS loops, ASRS units, and gantry systems, and ascertain that they could work together to facilitate the planned increase in throughput. In addition, the client also aimed to:
• Discover bottlenecks in the whole system. • Determine reasons for production loss. • Investigate the reasons why inventory was piling up in some zones. • Design best strategies to ensure efficient, smooth operations. Despite implementing modern infrastructure, the client faced several practical challenges, including irregular flow of Tyres, accumulation of inventory at inspection and loading areas, and inconsistent cycle times in the EMS system. These inefficiencies threatened to undermine the purpose of the expansion.PMI’s Approach: Multi-layered Simulation Study
In order to reveal the system's limitations and analyze its performance, PMI employed a systematic simulation process that integrated static analysis with dynamic 2D and 3D simulations. The simulations enabled visualization of real-time interactions and the discovery of latent inefficiencies in various parts of the system.
EMS Loop Simulation
The EMS loop, which had a vital part to play in moving Tyres from one station to the next, was analyzed in detail. Simulation involved detailed modeling of the loading and unloading stations as well as the operational logic that controls EMS carriers.
Analysis of ASRS
The ASRS building—with capacity for 7,000 Tyres—was monitored for input/output cycle times, throughput efficiency, and load processing patterns. PMI tested how the system reacted to inputs with different flow levels and under partial load conditions.
Review of Gantry Crane System
Covering a total area of 1,500 square meters with a handling capacity of 6,000 Tyres, the gantry system was assessed to provide maximum stacking, timely clearance, and harmonious integration in upstream and downstream operations.
Key Findings & Recommendations
EMS Loop Bottleneck at Unloading Stations
The simulation uncovered the fact that the EMS loop unloading stations were performing as critical bottlenecks. Delays at these points cascaded through to impact upstream activities, resulting in Tyres piling up in the system. PMI suggested adding an extra unloading station, which proved to ease the congestion and enhance overall system flow.
Ineffective EMS Carrier Utilization
The current logic provided for one Tyre to be carried by each EMS carrier. This sub-optimization caused insufficient carriers available and broke up Tyre supply from construction machines. PMI suggested that two Tyres be loaded on each EMS carrier, which increased the loop's capacity by 25% and reduced half the number of carriers needed—resulting in more even and efficient operations.
ASRS Inefficiency Due to Partial Loads
The ASRS had been frequently running short of consecutive Tyres of the same type. This resulted in idle time and low throughput. To solve this, PMI suggested discipline of operation at unloading points so that no order was left without monitoring. This modification allowed for better batching of similar Tyres, enhancing ASRS performance without structural alterations.
Tyre Mixing at Inspection and Conveyor Flaps
There was another problem at the inspection station, where Tyre mixing resulted in downstream gantry delays. As the gantry could inspect back-to-back tyres of the same type only, it had to wait for compatible sets to build up. The issue was traced back to intermittent conveyor flap behavior and unsynchronized inspection outputs. PMI suggested improving conveyor flap logic and adding a buffer in front of the inspection station to buffer and queue similar Tyres separately. This enhanced gantry efficiency and cut down on idle time.
Simulation Study to Validate the EMS Loop & Gantry System for a Tyre Manufacturer
Conclusion
With a combination of static and dynamic simulation methods, PMI gave the customer a definitive insight into the strengths and weaknesses of the new system in operation. Every simulation scenario was specifically designed to simulate realistic workflows, enabling accurate diagnostics and focused recommendations.
The results of the study enabled the Tyre manufacturer to:
• Increase throughput without further investment.
• Greatly minimize wait times and inventory stack-ups.
• Maximize use of resources and decrease reliance on further EMS carriers.
• Enhance consistency of flow in ASRS and gantry systems.
Finally, the simulation-based insights guaranteed that the client could fully take advantage of their infrastructure improvements, realizing the intended twofold increase in production capacity without compromising operation efficiency. The case is an ideal illustration of how digital simulation tools can be instrumental in verifying and optimizing intricate automated systems in contemporary manufacturing.
Supporting Video and Images
