Simulation of a Tyre Factory for a Leading Producer – New Plant
February 1, 2024
Simulation of a Tyre Factory for a Leading Producer – New Plant
mbawankar |
One of India’s Leading Tyre Manufacturers Planned to set-up a New Plant.
The molds used for TCM machines are very expensive. Changes in product types will result in high changeover times. Due to demands with high variety of product types and low volumes, planning TBM and TCM machines and adjusting batch sizes becomes very complex.
Key Points
- Tyre Industry
- Simul8
- Production Scheduling
- Capex Study
- Buffer Analysis
Client's Challenge
- Assist client in TBM and TCM production planning
- Define operational rules for its simplification
- Check feasibility of client’s equipment layout to meet production target
PMI's Approach
- The TBM and TCM setup was modeled with Simul8.
- Lead time, buffer and equipment utilization were quantified
- Modular concept was tested where separate modules were classified based on tyre sizes and were studied independently
Findings & Recommendations
We tested alternatives to existing methods where
- <Constant Flow Logic>
- <Trigger Logic>
We recommended the optimum number of equipment to ensure the plant can meet production target with an easier way of planning.
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