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CEAT - Halol
To capture greater market volumes, CEAT needed to incorporate greener materials and meet stringent in-process specifications. CEAT deployed Fourth Industrial Revolution use cases like advanced analytics to optimize cycle times and digitalization of operator’s touchpoints. As a result, the site reduced cycle times by 20%, process scrap by 46%, and energy consumption by 15% . Overall, this resulted in approximately a 2.5 times increase in export and OEM sales in two years.
INDIA | AUTOMOTIVE
CEAT - Halol
CEAT’S JOURNEY TO LIGHTHOUSE
WHAT ARE LIGHTHOUSES?
Lighthouses are those pioneers and leaders who have embraced innovation, sustainability and a vision to scale advanced technologies, throughout their production networks and beyond.
INDUSTRY 4.0 AT CEAT
In 2012, CEAT embarked on its digital transformation journey with the aim to improve productivity and increase energy efficiency. The digital journey for CEAT Halol started with the introduction of bar codes in PCR tyres and the MES platform on the shop floor. Over the next 5-6 years, work was done on digital projects that were mostly centered around individual use cases or in the pilot phase. Starting in 2019, the company has truly worked towards accelerated development and deployment.
As the first step, the company began by mapping and ensuring 100% digitalisation of operator touch points.
Industry 4.0 at CEAT
Among the biggest catalysts of the accelerated Industry 4.0 journey at CEAT was the company’s decision to grow its footprint in the export market, especially across Europe. The European market has stringent process specification requirements, including a preference for greener material. CEAT shifted its focus from a carbon base to a silica base, which would enable better rolling resistance and better wet grip in its products, which are key specifications mandated in Europe. The proportion of green materials used by CEAT in its production process more than doubled, from 28% to 57%. However, this has had an adverse impact on the overall cycle time and efficiency of the equipment, bringing down the overall capacity of the plant, its productivity levels and increase in scrap generation.
BUILDING EFFICIENT SYSTEMS THROUGH INDUSTRY 4.O
To address this problem area, an effective solution was eventually found in 4IR. CEAT was able to develop more than 30 use cases, touching every aspect of the production process, right from material procurement, manufacturing and warehousing to training and customer delight.
1. CEAT deployed 4IR technologies such as advanced analytics for dynamic process control, VR for operator training, visual analytics, digitisation initiatives such as large-scale IIoT, real-time visualisation and alerts, and closed looping.
i The implementation of 4IR use cases led to reduction in cycle times by 20%, lowering process scrap by 46%, and cutting down energy consumption by 15%. Overall, this intervention resulted in a ~2,5x increase in export and OEM sales in two years.
ii Digital has made life easier for those at the shop floor, in the following areas:
a) 200+ log-books/manual touch points across the shop floor have been eliminated.
b) The real-time quality dashboard has reduced overall TAKT time for major defect analysis from 3 days to 1 hour.
c) Leakages of steam and air are now predicted through the digital model, against quarterly audits done through manual interventions in the past.
2. Digital solutions in energy efficiency improvement projects have helped CEAT improve the overall carbon footprint of the plant. At normalised tonnage levels, GHG emission levels at Halol have reduced by more than 20% over the last two years, while water consumption has been brought down by over 30%.
3. The company has moved towards a paperless shop floor at Halol by digitising its process log books and check sheets, thereby eliminating nearly 75 types of physical log books.
4. Currently, CEAT is working towards implementing a Digital Nerve Centre that will help optimise its entire supply chain network.
5. The company is also working towards its sustainability vision of reducing carbon footprint by 50%, by 2030.
In terms of energy conservation, new approaches were adopted . The dynamic warmup system in the tyre curing press, and the compressed air optimisation using predictive analytics, are great examples of this new approach.”
On the manpower front, CEAT explored digital platforms that could help train its people faster and more efficiently, and set up a Virtual Reality (VR) station for machine operators. The VR platform ensures that people on the shop floor are trained faster, in a safer manner, and are able to deliver quality products from their first day of operating a new machine.
DRIVING COMPANY-WIDE ADOPTION OF 4TH INDUSTRIAL TECHNOLOGIES
During the transformation exercise, CEAT focused on four key aspects relating to the implementation:
Impact: Technology adoption should be in line with customer and business needs. It should be aligned with the business needs so that they have a clear impact on the topline and bottom line.
Integrated use case: 4IR use cases should be distributed across the shop floor with an end-to-end implementation approach, so that adoption happens across the value chain. It should not be treated as a niche exercise that is restricted to a few people.
Enabler/workforce engagement: People capability and transformation are the key enablers in this journey. Investments in people capability building, and the formation of a digital COE to have a more focused approach towards implementation, have been instrumental to the success of this exercise.
At the peak of its implementation, CEAT had more than 10 ‘agile teams’ working across various projects.
Technology platform: The company undertook a holistic upgradation of the technology stack, from L1 to L5 levels, and introduced edge and cloud computing.
THE NEXT CHAPTER IN THE LIGHTHOUSE JOURNEY
In next phase of implementation, CEAT intends to invite its network of contract manufacturers to the plant site, and upskill them to scale up their digital journey. Jayasankar adds, “We plan to conduct ‘Show and Tell’ sessions for our partners and other companies within the Group, to help them adopt 4IR technologies. The aim is to take digital beyond the four walls of the factory to our vendors/suppliers and to our supply chain partners to increase visibility and thus, resilience.”
the Daily Work Management (DWM) meeting at Halol has moved from conventional paper-based discussions to discussions based on digital platforms.
Through this exciting journey, CEAT has deployed a few industry-first solutions challenging conventional systems and working with a zero based approach towards problem solving. The use case of IoT-enabled intelligent controls for energy improvement, is one such case where 4IR technology has been used to bring down non-productive time in the curing process.
The company has already identified key digital deployment needs at its Chennai and Nagpur plants, which will take it further ahead it in its journey of Lighthouse and overall excellence.
CEAT's use of AWS
https://www.itnews.asia/news/ceat-turns-to-aws-to-build-smart-factory-intelligent-tyres-584318
https://ipfonline.com/news/detail/industrynews/ceat-excelling-manufacturing-with-ir4-technologies/15710
https://www.ceatspecialty.com/br/blog/company-announcements/ceat-gets-lighthouse-certification-from-world-economic-forum-for-halol-plant
https://auto.economictimes.indiatimes.com/news/tyres/halol-tyre-facility-of-ceat-wins-lighthouse-certification-from-world-economic-forum/97177487
https://www.magzter.com/stories/business/Manufacturing-Today/CEATS-HALOL-PLANT-A-BEACON-OF-INNOVATION
https://www.thehindubusinessline.com/companies/ceat-tyres-gets-lighhouse-certification-from-world-economic-forum-for-halol-plant/article66382538.ece
https://www.youtube.com/watch?v=n9odb4yWixA
https://www.linkedin.com/posts/ceat-tyres-limited_wef23-ceat-winning-activity-7021808819391377408-BlFI
https://www.zebra.com/content/dam/zebra_new_ia/en-us/solutions-verticals/vertical-solutions/manufacturing/success-story/manufacturing-success-story-ceat-india-en-ap.pdf
https://www.tyrepress.com/2018/07/ceat-plans-to-invest-us500-million-in-new-tyre-factory/
Bosch Automotive - Bursa - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
https://nraoiekc.blogspot.com/2024/04/bosch-automotive-bursa-industrial.html
Dr Reddy's - Hyderabad Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
List of Industry 4.0 Light Houses - WEF - McKinsey - Have You Benchmarked with the Best in Industry 4.0 Implementation?
https://nraoiekc.blogspot.com/2024/01/list-of-industry-40-light-houses-wef.html
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