Like many other sectors, India’s tyre industry is undergoing a massive digital transformation. Companies like CEAT have been at the forefront of this shift, adopting state-of-the-art technology.

The company was recently included in the World Economic Forum’s Global Lighthouse Network due to its impactful digital transformation using Fourth Industrial Revolution (4IR) technology.

The leading tyre manufacturer has also planned to extend its technological advancements to its Nagpur plant. “CEAT’s vision for a smart factory dates back to 2015, when it commissioned its Nagpur plant. The groundwork, however, was laid earlier at Halol, where barcode tagging was introduced for traceability and error-proofing. While Nagpur became the first facility to implement a manufacturing execution system (MES), deeper analytics and machine learning capabilities were not yet in focus between 2015 and 2020,” revealed Jayasankar Kuruppal, Sr Vice President –Manufacturing, during an exclusive interview with Tyre Trends.

As Halol expanded and exports to Europe surged by the early 2020s, CEAT had to rethink its manufacturing strategy, shifting from a high-volume, low-variant model to a high-variant, low-volume approach. Once limited to 60-70 stock-keeping units (SKUs), the company's passenger car segment expanded nearly fivefold to meet European demand, requiring a complete overhaul of production workflows. 

At the same time, the adoption of silica-based compounds, which is critical for wet grip and rolling resistance, posed new challenges. These materials inherently increased cycle times, impacting capacity utilisation. While Halol was not initially designed for high-silica production, the company’s Chennai plant incorporated necessary corrections. However, tighter OEM specifications and European market requirements led to higher scrap and yield losses. 

Recognising the limitations of conventional manufacturing, CEAT turned to 4IR technology to optimise its processes. The 4IR technology refers to the advanced digital and automation-driven technologies transforming industries today. It builds on the Third Industrial Revolution by integrating AI, IoT, big data and robotics to enhance efficiency and decision-making.

“The digital transformation began at the Halol plant, expanded to Chennai and is now planned for Nagpur. Between 2020 and 2022, CEAT developed and deployed over 80 digital use cases, earning its first Lighthouse Factory designation. This data-driven manufacturing approach is now being systematically rolled out across its entire production network,” added Kuruppal.

Intelligent factories

4IR plays a crucial role in tyre manufacturing and recycling by enhancing predictive maintenance through IoT sensors, increasing energy efficiency via AI, production optimisations and advancing smart tyres with real-time monitoring.

On the other hand, an intelligent or smart factory in tyre manufacturing is defined by two core pillars, namely automation and digital intelligence. Traditionally, the tyre industry has been labour-intensive, but the shift towards smart factories is transforming operations through seamless machine-to-machine communication, real-time data sharing and AI-driven decision-making. 

The first layer of an intelligent factory is pure automation. This includes automated machines for tyre handling, programmable logic controllers for managing machine operations and automated warehousing systems to ensure smooth flow.

“For a plant to be truly smart, data must move seamlessly across all these systems, creating a connected ecosystem. This integration extends to ERP systems and advanced AI/ML-powered analytics, optimising throughput and efficiency,” said Kuruppal.   

The next stage is where operations run end-to-end with minimal human intervention. CEAT has already implemented elements of this, particularly through curing-to-dispatch automation, where tyres move untouched from uniformity testing to segregation, grading, storage, retrieval and final dispatch. It also has AI-driven IoT integrations that enhance energy efficiency, yield optimisation and first-time-right accuracy across all processes.

“The fusion of AI, IoT and automation is enabling tyre manufacturers to move from traditional manual-heavy processes to a digitally orchestrated, high-efficiency production model,” quipped Kuruppal.

CEAT’s production capacity spans multiple plants, each specialising in different tyre categories. The Chennai and Halol plants both produce 20,000 passenger car tyres daily. The Nagpur plant, India’s largest two-wheeler tyre manufacturing facility under one roof, with a capacity of close to 78,000 two-wheeler tyres daily.

Digital implementation

Curing operations in CEAT’s passenger car and truck tyre segments are almost entirely automated. While the curing medium remains unchanged, continuing with a combination of steam and nitrogen across Halol, Chennai and other facilities, the company is also exploring radical new processes, though still in the proof-of-concept stage. 

One key digital use case implemented in Chennai focused on reducing steam consumption through real-time process monitoring. Traditionally, mould heating followed fixed time cycles (e.g. 120 or 150 minutes). CEAT optimised heating based on actual temperature data, cutting steam consumption by almost 30 percent by integrating sensors and applying a machine-learning model.

The manufacturer has invested approximately INR 450-500 million in capital expenditure across its three factories to implement automation and digital transformation initiatives. On the operational expenditure side, CEAT spends INR 60-70 million annually on software licenses, infrastructure upgrades, sensors and scanners to sustain these smart factory systems.

Adopting smart manufacturing technologies has led to significant cost reductions for CEAT. Factory conversion costs at Chennai and Halol have decreased by 20-30 percent, driven by lower energy consumption, improved yield, higher manpower productivity and throughput enhancements.

Lead times from order placement to tyre dispatch have been cut by 50-55 percent, significantly improving supply chain efficiency. Additionally, material wastage has been reduced with process scrap, both component-level and finished product waste, dropping by 25-30 percent, resulting in substantial raw material savings.

Alluding to how difficult was it to implement such extensive digital changes, the executive explained, “From an infrastructure standpoint, Chennai had a clear advantage over Halol since the latter was commissioned in 2010 and 2015, when network and digital infrastructure were not as advanced. Unlike Chennai, Halol still does not have a fully integrated MES, making digital transformation more complex.”

“However, the approach to smart manufacturing differed at both plants. At Halol, the primary focus was on efficiency improvements. In contrast, Chennai underwent a more comprehensive transformation, covering the entire manufacturing chain from design and production to dispatch and supply chain optimisation. The goal at Chennai was to reduce overall turnaround time, significantly cutting the cycle from customer order receipt to final dispatch,” he added.

While Chennai benefited from a stronger digital foundation, CEAT did not merely replicate Halol’s use cases but developed new ones tailored to Chennai’s specific needs, further driving end-to-end operational efficiency.

Commenting on the challenges surrounding this paradigm shift, the executive noted, “Integrating legacy systems with Industry 4.0 technologies posed a significant challenge as ensuring compatibility between older manufacturing infrastructure and new automation, IoT and AI-driven solutions required meticulous planning and phased implementation.”

“Another critical hurdle was maintaining data quality and governance, necessitating robust validation processes, data lineage tracking and an accountability framework to enhance data integrity and reliability,” he added.

Answering whether such transformation is possible on OTR production lines, he said, “Unlike passenger or two-wheeler tyres, OTR tyres have a longer cycle time and high levels of customisation, making digital automation less complex but highly specific. While digital transformation is feasible, CEAT plans to prioritise full automation at Nagpur in the next 18–24 months, before shifting focus to digitalisation in OTR production.”

Workforce re-alignment

CEAT is reshaping its workforce strategy to align with its digital transformation, ensuring that shop floor employees are equipped and actively involved in adopting new technologies. 

It has digitised over 100 operator touchpoints to secure operator buy-in. The programme simplifies shop floor tasks through digital tools, MES integration and real-time dashboards, allowing operators to make decisions independently and reducing reliance on supervisors. Every operator has undergone basic digital awareness training to facilitate this transition. 

A key move was the introduction of business translators, who are frontline supervisors with strong technical acumen. They bridge shop floor pain points with digital solutions. Working alongside data engineers and scientists, these individuals co-develop AI-driven use cases, such as reducing setup time in mixing processes to improve efficiency. 

The company also strengthened its talent pipeline, hiring computer science graduates, a rarity in the tyre sector just a few years ago.  It has pioneered hiring female operators in the tyre industry, beginning in Halol in 2009.

“Today, 24–30 percent of shop floor employees in Chennai and Nagpur are women. While digitalisation isn’t the primary driver of this shift, automation has made traditionally labour-intensive jobs more accessible. The company also enforces pro-women policies, including home pick-ups and drop-offs, designated rest areas, female security and an internal support forum (V Power) to address workplace concerns,” informed Kuruppal.   

When asked whether digitisation will lead to a cut in vacancies, Kuruppal stated, “Contrary to fears that digitalisation reduces shop floor jobs, we find ourselves grappling with the bigger challenge of talent attraction. Post-pandemic, fewer young workers are willing to pursue manufacturing roles, with many opting for finance, retail and IT-driven careers instead. This trend is evident across major tyre-producing states like Tamil Nadu, Maharashtra and Gujarat.” 

“While automation and AI reduce physical strain and deskill certain operations, a fully manless tyre plant remains economically impractical in the near term. However, with rising labour costs and shrinking workforce interest, a fully automated future – perhaps within 15–20 years – isn’t off the table,” he added.

Sustainability through digitisation

CEAT is driving sustainability through digital transformation, reducing energy and water consumption while lowering its carbon footprint. Energy efficiency measures have led to a 15 percent reduction in power consumption at Halol and 25 percent at Chennai.

Renewable energy accounts for 40 percent of the company’s power mix, cutting Scope 1 and Scope 2 carbon emissions by nearly 30 percent. Water usage has been reduced by 30-35 percent over the past three years through steam optimisation, with future plans to eliminate steam in curing.

In green material adoption, integrating silica-based compounds in tyre manufacturing has required process adjustments as it increases cycle time. CEAT collaborates with equipment manufacturers to enhance efficiency. It has upgraded mixers to improve silica processing and support its shift towards sustainable materials.

Commenting on future plans to implement digital solutions, Kuruppal said, “We plan to integrate virtual and mixed reality into the manufacturing processes to enhance equipment maintenance and reduce mean time to service. We are also exploring AI-driven process optimisation, as these models will auto-correct processes in real-time, enhancing product consistency and accelerating decision-making. These technologies will also help identify and eliminate bottlenecks in manufacturing and planning, ensuring a more agile and efficient production flow.”

“The company is looking into GenAI to address complex operational challenges. AI-driven predictive maintenance will improve equipment reliability by forecasting potential failures before they occur. Additionally, GenAI will optimise supply chain and production planning, ensuring better resource allocation and efficiency,” he added.  

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Prinx Chengshan took part in the SHACMAN Group Worldwide Partnership Conference in Xi'an on 15–16 October, where dealers, key accounts and industry partners from across the globe gathered. The company attended as a core strategic partner of SHACMAN and acted as exclusive tyre sponsor of the vehicle stunt show, joining domestic and international customers to examine fresh opportunities in the global commercial vehicle sector and help shape a new model of collaborative industry growth.

Cooperation between the two firms has deepened since 2024, centring on original equipment fitment for flagship high-end models including the Delong X5000 and X6000, with products offered domestically and overseas. Dependable product quality and supply chain assurance have enabled Prinx Chengshan to grow into a core tyre supplier to SHACMAN, consistently furnishing tyre solutions for its flagship ranges.

A dedicated stunt driving segment formed part of the conference, with Prinx Chengshan as sole tyre exhibitor backing the performance vehicles. Cars fitted with Chengshan XSTANCE PRO S10 and CDR621 tyres carried out sustained drifts, high-speed turns and other demanding manoeuvres, remaining stable even under extreme conditions such as tyre burnouts and showing strong wear resistance.

Li Wenli, a three-time national truck racing annual finals champion known as China's top heavy truck driver, rated the tyres highly for grip, durability and handling stability. Live demonstration in place of specification presentations made technical strengths tangible, letting partners observe stability under extreme friction and high-torque loads.

The conference allowed the company to strengthen mutual trust and communication with SHACMAN and to showcase its commercial vehicle tyre capabilities; at its 50th anniversary milestone, Prinx Chengshan reiterated its commitment to keep improving its global service network, advance alongside SHACMAN on a new globalisation journey and help build an industrial ecosystem defined by mutual benefit and collaborative development.

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Michelin has opened a 1,000 sq ft tyre and service store in Jammu in partnership with Maha Shakti Auto, expanding its retail presence in the northern Indian city.

The Michelin Tyres & Services (MTS) outlet is located in Main Bazar, Gumat, in Jammu’s commercial district. It will serve customers in the city and surrounding region, offering tyres for passenger cars, two-wheelers and commercial vehicles.

The store stocks Michelin’s Primacy, Pilot Sport, Latitude Sport and LTX Trail tyre ranges. Its facilities include wheel alignment and balancing systems, automotive accessories, and mechanical repair and maintenance services.

The outlet was inaugurated by Benjamin Coesnon, Marketing Director for India at Michelin, alongside the Maha Shakti Auto team.

Shantanu Deshpande, Managing Director of Michelin India, said “Jammu is an important market in Michelin's growth in North India. Its role as a regional trade and transit hub is creating steady demand for safe, reliable and high-performance mobility solutions. Our new Michelin Tyres & Services store brings Michelin's globally benchmarked products and services closer to customers in the region. Building on our recently launched Made-in-India Primacy 5, we will keep delivering mobility solutions tailored to the evolving needs of Indian consumers."

The company said the store was designed to address driving conditions in the region, where steep gradients, sharp curves and changing weather make tyre grip, braking stability and durability important considerations.

Maha Shakti Auto has 30 years of experience in Jammu’s automotive aftermarket, according to Michelin. The partnership combines the local business’s technical expertise and market knowledge with Michelin’s tyre technology and product range.

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The Yokohama Rubber Co., Ltd. has announced that the No. 77 BMW M4 GT3 EVO, fielded by Schubert Motorsport and fitted with the company's ADVAN global flagship tyres, secured the NLS Speed Trophy series championship. The award goes to the team accumulating the most points across all classes throughout Germany's Nürburgring Langstrecken-Serie (NLS). As the series champion in the NLS premier SP9 Pro class, the No. 77 also claimed a KW Team Trophy, presented to the car and team with the highest points total in each class.

This season marked Yokohama Rubber's role as an official partner of BMW M Motorsport in the NLS, with the No. 77 BMW M4 GT3 EVO carrying ADVAN colouring. Across the 10-round campaign, the ADVAN-shod No. 77 produced consistently strong results, earning two overall victories and two second-place finishes. The ADVAN A005 for dry conditions and ADVAN A006 for wet conditions supplied the grip and durability needed to contend in fiercely competitive races across varying weather. ADVAN-equipped cars had previously taken the NLS Speed Trophy in 2020 and 2023.

Beyond the NLS, Yokohama Rubber partnered with BMW M Motorsport at May's ADAC RAVENOL 24h Nürburgring. The No. 77 ADVAN-coloured entry placed 8th overall and 7th in the SP9 class, while BMW M Motorsport's No. 81 BMW M3 Touring 24H, also on ADVAN tyres, took 4th overall and 1st in the SP-X class.

Under its three-year (2024–2026) medium-term management plan, Yokohama Transformation 2026 (YX2026), the company's consumer tyre strategy seeks to maximise sales ratios of high-value-added tyres by expanding the ADVAN and GEOLANDAR brands, winter tyres and 18-inch and larger products. Yokohama Rubber views motorsport participation as vital to strengthening ADVAN and GEOLANDAR, and continues to compete in a wide range of events worldwide, from top-category to grassroots racing.

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Prinx Chengshan presented its Chengshan brand at the 140th China Import and Export Fair, which opened in Guangzhou on 15 October. The Canton Fair, known as China's leading trade event, has a history of nearly seven decades and functions as an indicator of the country's foreign trade while offering Chinese brands a platform to demonstrate innovation and meet international buyers.

At the fair, the company highlighted products including the ET16 wide-body dump truck tyre, whose wide and deep transverse tread grooves provide strong traction for smooth starts on soft, uneven mining terrain and help lower risks such as wheel slip and vehicles becoming stuck. The ELD12 loader tyre was also featured for its wear resistance and load-bearing capacity across demanding conditions, with resistance to excessive deformation under heavy loads supporting stable and safe equipment operation.

The participation coincides with Chengshan Group's 50th anniversary and Prinx Chengshan's accelerating global expansion. Founded in Rongcheng, Shandong Province, in 1976, the company now operates three production bases, two R&D centres, three sales centres and four technical centres worldwide. On 9 October, its Malaysia plant produced its first tyre less than 11 months after construction began, marking progress in overseas production and supply chain resilience.

Prinx Chengshan has also increased investment in the off-the-road tyre segment, operating a green and smart OTR tyre factory in Shandong and achieving mass production of giant tyres in sizes including 27.00R49, 30.00R51 and 33.00R51, while rolling out its first 57-inch giant tyre, size 46/90R57. Its OTR products serve mining, construction, ports, airports, agriculture and industrial operations, offering system solutions for global agricultural mechanisation, engineering projects and resource development.

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