Simulation of a Tyre Factory for a Leading Producer​ – Conveyer System

February 1, 2024

Simulation of a Tyre Factory for a Leading Producer​ – Conveyer System


mbawankar |

One 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

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