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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Hankook Tire has further solidified its global reputation for innovative product design after securing three Winner awards in the Product Design category at the prestigious Red Dot Design Award 2026. The recognition from the internationally acclaimed competition underscores the company’s commitment to advancing tire technology through aesthetic and functional excellence.

The honoured products include the ultra-high-performance Ventus evo, the all-terrain iON AT developed for electric SUVs and pickup trucks and Laufenn’s summer performance tyre, the S FIT2. Each design was evaluated for its innovation, aesthetics, functionality and overall quality, with Hankook Tire standing out among global contenders in this year’s selection.

The Ventus evo was distinguished by its sharply defined centre wheel groove that enhances steering precision and reduces road noise, while a chamfer design and an AI-powered sustainable compound improve mileage by up to 32 percent. Its sidewall also features a Vanta Velvet graphic with an ultra-fine texture, combining visual appeal with practical performance. Meanwhile, the upcoming iON AT integrates key electric vehicle attributes such as energy efficiency, extended mileage and low noise into an off-road focused structure, with an optimised tread pattern and compound that minimise energy loss, heat generation and wear.

The S FIT2 from Laufenn earned recognition for its Numeric Sidewall design, which aligns with the brand’s minimalist philosophy while strengthening visual identity. Its asymmetric tread pattern ensures precise handling and effective drainage, while added features like the Alignment Indicator and EV Mark enhance user convenience. Environmentally conscious technologies also extend tread life and reduce noise. Organised by Germany’s Design Zentrum Nordrhein Westfalen, the Red Dot award is one of three major international design accolades – alongside the iF Design Award and the IDEA – where Hankook Tire continues to earn consistent recognition, reinforcing its premium brand image through innovation-driven design.

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HS HYOSUNG Group has officially released its inaugural Sustainability Report, marking a significant milestone since the conglomerate’s establishment. The comprehensive document provides a transparent overview of the organisation’s Environmental, Social and Governance management activities, detailing both ongoing initiatives and notable accomplishments across its operations.

The publication consolidates ESG data from the holding entity, HS HYOSUNG Corporation, and extends to major subsidiaries such as HS HYOSUNG USA, Inc., HS HYOSUNG TOYOTA Co., Ltd. and HS HYOSUNG GLOBAL LOGISTICS VINA CO., Ltd. Furthermore, the report incorporates the ESG performance of key affiliates, including HS HYOSUNG ADVANCED MATERIALS Corporation and HS HYOSUNG INFORMATION SYSTEMS Corporation, ensuring a holistic representation of the group’s sustainability efforts.

Central to the report is the introduction of the group’s sustainability vision, ‘Rooted in Value, Growing Together’, which is supported by three strategic pillars: Growth Value, Shared Value and Trusted Value. To guide its strategy, the group synthesised double materiality assessments from various units, identifying five Group-wide priorities: customer satisfaction, occupational health and safety, compliance, eco-friendly portfolio and climate change response. The report systematically details the management frameworks, current progress, key achievements and forward-looking plans for each of these critical areas.

An HS HYOSUNG official said, "Publishing our first Sustainability Report as we celebrate the second anniversary of HS HYOSUNG makes this milestone especially meaningful. Going forward, we will continue to respond proactively to a changing business environment while creating greater value and building stronger trust with our stakeholders."

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Tegeta Green Planet, in collaboration with Shine Energy, recently conducted an environmental awareness session at Edison School ‘Novatsia’, drawing the participation of approximately 60 students. The gathering was designed to illuminate the core tenets of the green economy, renewable energy and circular economic models, aiming to instil a robust sense of environmental stewardship among the younger generation.

The initiative sought to cultivate a collective sense of duty regarding the preservation of natural resources and the urgent challenges posed by climate change. Attendees were briefed on the deployment of modern technologies and innovative strategies to mitigate ecological footprints while also exploring the corporate sector's role in fostering a sustainable future. The discourse underscored that sustainable development transcends mere environmental conservation, integrating economic vitality and social equity.

Tegeta Green Planet’s representatives delved into the specifics of the Extended Producer Responsibility system and the intricacies of managing particular waste streams, alongside the foundational principles of the circular economy. Concurrently, Shine Energy’s team elaborated on the pivotal function of renewable sources in the ongoing energy transition, highlighting the societal and ecological advantages of solar power and other clean energy alternatives. The session was notably enriched by the proactive engagement of 10th-grade students.

These students delivered presentations on Earth Day, tracing its historical origins, its evolution into a global movement and the critical importance of individual action in resource preservation. The dialogue reinforced that every societal member contributes to this balanced vision. Tegeta Green Planet and Shine Energy remain committed to expanding such educational projects across various institutions, viewing them as essential to nurturing an environmental culture and responsible behaviours that are fundamental for the well-being of future generations.

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The U.S. Tire Manufacturers Association (USTMA) has launched National Tire Safety Week 2026, a public education campaign running from 29 June through 4 July. This year’s initiative, themed ‘Driving Safety, Full Circle’, introduces a new storytelling platform called Full Circle, which emphasises the essential role of tyres in everyday American life. The campaign underscores the critical importance of regular tyre maintenance for overall vehicle safety.

To illustrate this message, the association has released Full Circle Moments, a series of short videos depicting common scenarios where tire performance is paramount. The series features five distinct vignettes, including an infant’s secure journey home from the hospital, a parent’s lesson in driving for a teenager, the durability required for a family road trip, the traction needed during a heavy rainstorm and the stopping power necessary for sudden braking. These videos are being distributed via USTMA’s official website and social media channels.

The campaign also provides motorists with a practical maintenance guide, urging them to remember the acronym ‘P.A.R.T.’, which stands for Pressure, Alignment, Rotation and Tread. Drivers are advised to conduct these checks at least monthly and prior to embarking on extended summer road trips. According to the association, investing a few minutes in these simple inspections can significantly reduce the risk of highway incidents.

Furthermore, National Tire Safety Week marks the official launch of the Full Circle digital platform, which is structured around five core pillars: safety, sustainability, innovation, economic impact and advocacy. The site offers evidence-based narratives about the tyre industry’s dedication to reliable mobility and environmental stewardship, including efforts to repurpose tyres. The initiative is supported by all major USTMA member companies, including Bridgestone, Continental, Goodyear, Michelin and several other leading tyre manufacturers.

Anne Forristall Luke, President and CEO, USTMA, said, “Every drive home, every family road trip, every race to an emergency by a first responder happens on tyres. Proper tyre maintenance plays a critical role in safety on the road, and we must all do our part to protect the people and moments we value most. National Tire Safety Week is our reminder that caring for our tyres is simple and essential, and that behind every safe mile is an industry working to make mobility safer, smarter and more dependable.

“Tyres are essential to nearly every part of modern life, yet they’re easy to take for granted. Full Circle embodies the depth of our industry’s commitment to the communities we serve. It’s a story of an industry committed to continuous progress with safety at the forefront, and we’re proud to keep driving it forward.”

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