When the World Economic Forum inducted CEAT’s Chennai facility into its Global Lighthouse Network in January 2025, it made the Indian tyre-maker the first tyre brand in the world to hold two such honours – Chennai following in the footsteps of the company’s Halol plant. Add to that CEAT’s Deming Grand Prize, awarded by the Union of Japanese Scientists and Engineers for sustained excellence in Total Quality Management, and the company finds itself in rarefied company: one of only a handful of manufacturers worldwide, and the only tyre brand to hold both distinctions.

Behind these accolades sits a quieter, harder story – one of culture change, shop-floor scepticism and years of disciplined, incremental investment in artificial intelligence, the Industrial Internet of Things and automation. In an interview with Tyre Trends, Jayasankar Kuruppal, Senior Vice President, Manufacturing at CEAT, spoke on what these recognitions actually mean on the factory floor, and where the company believes manufacturing is headed next.

AWARDS AS A BY-PRODUCT, NOT THE GOAL

CEAT’s Chennai plant has posted striking numbers since its digital transformation began: a 54 percent improvement in dispatch turnaround, a 25 percent uplift in labour productivity, an 18 percent reduction in cycle times, a 31 percent improvement in operating cost and a 47 percent cut in Scope 1 and 2 emissions. Yet Kuruppal is quick to reframe the narrative around these achievements.

“The awards are lagging indicators, not the goal. What actually matters is what they force us to build: a common language for problem-solving across every plant, real-time visibility into quality and efficiencies and a workforce that trusts data over gut-feel,” Kuruppal said.

“That discipline shows up directly in the numbers – tighter process capability, better efficiencies and faster changeovers leading to shorter lead times. There is a commercial dividend too: global OEMs increasingly audit manufacturing maturity, and being part of the WEF Global Lighthouse Network gives us instant credibility in those conversations,” he added.

WHAT’S REALLY DRIVING THE INVESTMENT

CEAT has been pouring capital into AI, IIoT and automation across its plants. Is this cost pressure, premiumisation or a simple need to stay globally competitive? Kuruppal’s answer suggests it is all three, each playing a distinct role.

Kuruppal explained, “Quality, cost and efficiency is what gets the funding approved. Premiumisation is what’s shaping which lines we automate or upgrade first – you cannot hold the tolerances a premium radial demands with manual, operator-dependent processes.” According to him, global competitiveness, meanwhile, sets the ambition. “We’re not benchmarking ourselves against the best tyre plant in India anymore – we’re benchmarking against the best factories in any industry,” he added.

Asked to rank the three forces, he summarised neatly: competitiveness sets the ambition, premiumisation sets the sequencing and cost discipline keeps the whole effort honest.

REPLICATING HALOL AT CHENNAI: CULTURE OVER CODE

Chennai’s transformation built directly on lessons learned at Halol, the world’s first tyre facility inducted into the Lighthouse Network. And when asked what proved hardest to replicate, the technology, the culture or getting the underlying processes right, Kuruppal said, “Technology was actually the easiest part to copy. A use case that works at Halol can be re-deployed at Chennai in weeks.”

But the real difficulty, as per Kuruppal, was culture, people and change management. At Halol, habits such as daily data reviews, operator ownership of quality metrics and a managerial focus on coaching rather than firefighting were built steadily over several years. Chennai, by contrast, has had to replicate that trajectory on a compressed timeline, with a workforce encountering these practices for the first time.

“We had to resist the temptation to just parachute in dashboards and call it digital. We spent real time getting the underlying process standardisation right first, because AI on top of an unstable process just gives you a faster route to the wrong answer,” Kuruppal said.

Jayasankar Kuruppal, Senior Vice President, Manufacturing, CEAT

WHERE THE RETURNS SHOW UP – AND WHERE THEY HAVEN’T YET

The productivity and dispatch gains at Chennai, he explained, hit the balance sheet in different ways. The productivity improvement lowers conversion cost per tyre and improves absorption of fixed costs as volumes grow. The dispatch improvement is more of a customer-experience story: less finished-goods inventory sitting idle, and OEMs and dealers receiving faster, more predictable delivery windows – ‘which matters a lot when you’re chasing premium and export business’.

Not every initiative has paid off yet, however. Kuruppal was candid about the areas still short of return, singling out ‘some of the more exploratory AI use cases – like computer-vision pilots – which need more data cycles before the accuracy justifies scaling them further’.

QUALITY, MAINTENANCE, OUTPUT: AI TOUCHES ALL THREE

Rather than picking a single area where artificial intelligence delivers most value, Kuruppal argued that its power lies in the way it now touches quality, maintenance and output simultaneously – and that these reinforce one another. “Better quality data feeds better predictive-maintenance models, which reduces unplanned downtime, which directly lifts output,” he said. The most immediate impact shows up in more consistent product quality, higher yields and earlier detection of equipment issues. He pushed back, though, on the idea that AI at CEAT is a single flagship project: “On our floor, it’s dozens of narrow, specific use cases, each solving one operator’s or one supervisor’s actual problem.”

JUSTIFYING THE SPEND IN A MARGIN-TIGHT BUSINESS

Tyre manufacturing is not a business with room for indulgent technology spending, and Kuruppal was clear that CEAT does not fund innovation for its own sake. “Every use case has to show a clear line to quality, efficiency, cost or capacity enhancement before it gets budget,” he said. The company deliberately starts small – piloting on a single line, proving value with real production data, and scaling only what works – a discipline that means ‘the savings from scaled use cases fund the next round of pilots’. He offered a broader rationale too: in a commodity-adjacent business where raw material costs sit largely outside a manufacturer’s control, manufacturing capability itself becomes the differentiator. “If we can’t always control input costs, we can control how efficiently and consistently we convert them into tyres,” he added.

CHENNAI PLANT WIDENS ITS PREMIUM PUSH

CEAT on Oct. 1 announced an expansion of manufacturing capabilities at its Chennai plant across passenger car and SUV, commercial vehicle and two-wheeler tyres. The company said the move targets premium customers in India, Europe and North America.

What’s new

Cars and SUVs: The plant now makes the SportDrive SUV ZR22. CEAT said this makes it the first Indian tyre company to manufacture 22-inch tyres in India. It also makes the 4SeasonDrive+ all-season tyre and the CrossDrive RT rugged-terrain tyre, built for the U.S. market.

Trucks and buses: The plant can now produce seven advanced truck and bus radial sizes, including wide-base tyres that can replace dual-tyre setups, and low-profile sizes. CEAT is also scaling light truck steel radials in 15-, 16- and 17.5-inch sizes.

Two-wheelers: The SportRad Racing Slick range targets track use, and SportRad ST is a sport-touring range for motorcycles above 650cc.

“This investment strengthens our ability to compete in premium segments with products developed and manufactured in India,” CEAT managing director and CEO Arnab Banerjee said.

The 163-acre plant in Sriperumbudur, Kanchipuram, runs on connected machinery and real-time analytics. It also has a 9 MW rooftop solar installation and operates as a zero-liquid-discharge facility.

FROM PILOT TO SCALE: AN OPERATING-MODEL PROBLEM

With a large share of CEAT’s lines now running as ‘smart lines’, when asked what changes when a company moves from isolated pilots to scaling technology across multiple plants, the CEAT executive explained, “The problem changes completely. A pilot is a technology and data-science problem – get the model working, prove the use case. Scaling is an operating-model problem – standard work, training, change management, IT infrastructure that can handle load across sites and governance so every plant isn’t reinventing its own version of the same solution.”

CEAT has built what he calls a central playbook – reusable architecture, common data standards and the ability to roll a proven use case out to a new plant in weeks rather than months. “Just as importantly, ownership shifts: at pilot stage, a project team owns the initiative; at scale, it must become the plant’s own way of working, run by operations rather than a digital team sitting alongside it,” he added.

BRINGING 80 PERCENT OF THE WORKFORCE ALONG

CEAT reports that more than 80 percent of its workforce is now digitally enabled – a transformation Kuruppal admits did not come without resistance. “Yes, and I’d be understating it if I said otherwise,” he said. Crucially, he insists the resistance was never really about technology itself but about ease of operation. What worked, he explained, was making tools visibly useful to the person using them first – an operator seeing a dashboard that helps them hit their own target before it ever becomes a management reporting tool. CEAT invested heavily in shop-floor-specific training rather than generic digital-literacy courses and made a point of promoting from within, demonstrating that digital skills opened up better roles rather than closing off old ones. The company has also created new shop-floor roles beyond data scientists and engineers – ‘Business Translators’ and ‘Champions’ who act as torchbearers driving scaled implementation and wider blue-collar involvement.

CONSISTENCY, NOT JUST DEFECT COUNTS

Asked whether tighter process control has genuinely reduced defects, Kuruppal reframed the question around consistency. “Tighter process control means less batch-to-batch variation, which matters enormously in tyre manufacturing because so much of performance and durability comes down to material consistency through mixing, extrusion and curing,” he said. Real-time monitoring now catches drift early, rather than at final inspection – both a quality win and a material-efficiency win, in the form of less scrap and rework. The habit that has changed most, he said, is that quality data now drives daily decisions on the shop floor, rather than featuring only in a monthly review.

MANUFACTURING FOR A PREMIUM, ELECTRIC FUTURE

CEAT’s push into premium tyres calls for a step-change in manufacturing discipline. “Premium tyres are far less forgiving of variation, so the shift starts with tightening process capability across every stage – not just final inspection. That means more precise equipment, better process capability and closed-loop control,” said Kuruppal. In this context, flexibility takes on a different meaning: a wider SKU mix, smaller batch sizes and faster changeovers are pushing the company towards more modular manufacturing, alongside a workforce increasingly weighted towards process engineering expertise.

Electric vehicles introduce an additional layer of complexity. EV tyres must carry greater weight, handle instant torque and operate more quietly, tightening specifications around structural strength, noise and rolling resistance beyond those of conventional tyres. On the shop floor, that translates into new compound formulations requiring precise mixing, reinforced construction demanding tighter control of building machines and significantly lower tolerance for micro-variation.

CEAT’s existing leadership in the e-two-wheeler tyre segment, Kuruppal noted, is already feeding lessons – particularly on noise and efficiency – into how the company prepares lines for growing e-four-wheeler volumes in India.

SUSTAINABILITY AND RESILIENCE, BUILT IN

Sustainability, once a separate reporting exercise, is now ‘a line item in almost every manufacturing decision’, with energy and emissions sitting alongside cost and quality when evaluating new processes or equipment – Chennai’s 47 percent emissions reduction being the clearest proof point. Resilience, too, has become as much a data problem as a sourcing one. “Real-time visibility into inventory, machine health and production schedules means we can see a disruption coming and reschedule around it rather than reacting after a line has already stopped,” Kuruppal said, pointing also to greater flexibility in shifting product mix between lines and earlier warning signals from digitised supplier and logistics data.

SPEED AS A COMPETITIVE WEAPON

Manufacturing speed and flexibility, Kuruppal argues, have become one of CEAT’s most important competitive dimensions, as OEMs compress their own development cycles and expect tyre partners to match their pace – faster prototyping, faster line trials, faster ramp-up to volume. Chennai’s faster dispatch turnaround is part of the same story. “It’s not just about making tyres faster; it’s about the whole chain from order to delivery being more predictable and quicker,” he said.

GROUND STILL TO COVER

For all its Lighthouse credentials, Kuruppal was refreshingly honest about the distance still to travel. “Being part of that network is genuinely humbling. You see factories in electronics and consumer goods running end-to-end AI-driven planning and quality systems at a level of maturity we’re still building towards – particularly in advanced analytics for demand-and-production planning and in scaling generative-AI use cases beyond pilots,” he said. CEAT’s strength, he believes, lies in shop-floor execution and quality; the next frontier is connecting that data seamlessly across the full value chain, from raw-material sourcing to the end customer.

MANUFACTURING AS A GROWTH DRIVER

Perhaps the most striking shift Kuruppal describes is a change in how manufacturing itself is perceived within the business. “Traditionally, manufacturing was viewed in this industry as a cost centre that executes what sales and product teams decide,” he said.

“Today, our manufacturing capability is directly opening up premium and export opportunities, because global customers evaluate factory maturity as part of their sourcing decision. It works in the other direction too, shaping which premium and EV products the company can confidently commit to launching. Manufacturing has moved from being an execution function to being a genuine input into growth strategy,” he added.

WHAT COMES NEXT

Looking ahead, Kuruppal frames the next horizon as connecting what CEAT has built plant-by-plant into a single, integrated digital thread – spanning raw-material and demand planning, production and distribution – so decisions are optimised end-to-end rather than site-by-site. Generative AI, he said, is increasingly being explored for process and equipment troubleshooting and knowledge capture, making the expertise of CEAT’s best engineers accessible across every plant. Sustainability, meanwhile, will be designed into new lines from the outset rather than retrofitted. “The common thread is moving from isolated smart use cases to a genuinely integrated smart manufacturing system,” he explained.

THE ONE NUMBER THAT MATTERS

Answering the question on if he could track just one metric across every CEAT plant, what would it be, he admitted, “If I’m honest, no single number tells the whole story, but if forced to pick one, it would be Overall Equipment Effectiveness – OEE.”

“As a composite of availability, performance and quality, a healthy and rising OEE generally signals that machines are running, running at the right speed and producing good tyres – which is really the definition of a plant working as it should,” he said. It has its limits – OEE alone won’t reveal a lapse in safety culture or the pace of digital adoption – which is why, in the end, Kuruppal names two figures he watches above all: OEE and safety indicators.

The Goodyear Tire & Rubber Company has announced that Mark Stewart has stepped down from his roles as Chief Executive Officer and President of the company and has also left its board of directors, effective immediately. In his place, the company has installed board member Roger Wood as interim Chief Executive Officer, with Wood leading the tyre maker while a leading executive search firm helps the board identify a permanent successor.

Wood joined the board in 2023 and has spent over 30 years leading businesses in the automotive and manufacturing sectors. He was previously Co-Chief Executive of Tenneco Inc., which designs, manufactures and distributes clean air, powertrain and ride performance systems worldwide for vehicle manufacturers and the aftermarket, and he holds board seats at PHINIA Incorporated and Brunswick Corporation. As part of taking the interim role, he has given up chairing the board's human capital and compensation committee.

Earlier this year, the board set up a special committee to scrutinise the company's businesses and operations, seeking ways to lift performance and deliver more value to shareholders. Directors and management are pursuing that effort through a wide-ranging assessment of strategic and operational options, among them refining the business mix and footprint, sharpening efficiency and funding new products and capabilities that underpin long-term growth. No further updates are planned unless and until the board concludes that more disclosure is warranted or required.

In a separate announcement dated 27 October 2026, Goodyear said Jerome Rouquet will become Executive Vice President and Chief Financial Officer on 1 December 2026. Rouquet, now Chief Financial Officer at Visteon Corporation and formerly a senior finance executive at Tenneco and Federal-Mogul, takes over from interim Chief Financial Officer Scott Deakin, who will help ensure a smooth handover.

Joe Hinrichs, Goodyear Board of Directors Chair, said, "Goodyear has made meaningful progress in becoming a more efficient and focused company, and the board believes this is the right moment to transition leadership to accelerate that progress and capture additional opportunity. Roger brings extensive automotive and industrial CEO experience, deep operational expertise and strong relationships across OEMs and aftermarket customers. He knows Goodyear, understands the opportunities ahead and has the board's full confidence to bring heightened focus and urgency to execution while we conduct a thorough search for a permanent CEO. We thank Mark for his contributions to Goodyear.

"The board formed a special committee earlier this year to conduct a rigorous strategic review of the company to help strengthen performance and create shareholder value. The board, together with the Enterprise Transformation Office, is evaluating a broad range of strategic and operational opportunities, and we are committed to taking the right actions to position Goodyear for stronger performance and long-term success. We look forward to providing an update as this work progresses."

Wood said, "Goodyear has iconic brands, talented people and significant opportunities to improve performance and deliver long-term value. As I step into this role, my immediate priorities are to support our associates and customers, sharpen execution and build on the work already underway to advance Goodyear's transformation. I look forward to working closely with the board, leadership team and the Enterprise Transformation Office to advance the strategic review and translate that work into actions that strengthen performance and position Goodyear for long-term success."

Michelin Group has appointed Terry Redmile as Chief People Officer for Michelin North America, Inc. In his new capacity, he will direct employee-focused operations throughout the North America Region, encompassing the recruitment, growth and retention of leading talent. His appointment places a seasoned internal leader at the helm of the company's people strategy.

A veteran of over three decades with Michelin, Redmile started as a co-op student at the firm's Greenville research and development centre. His tenure has spanned roles such as quality engineer and site director at the Fort Wayne, Indiana, manufacturing plant, culminating most recently in his position as senior vice president of manufacturing operations for the Americas. He also holds an MBA from Clemson University and a mechanical engineering bachelor's degree from the Georgia Institute of Technology.

Matthew Cabe, President and CEO, Michelin North America, Inc., said, “Terry understands our business, but more importantly, he understands our employees. His foundation in manufacturing and engineering gives him a firsthand understanding of where so many of our employees work every day and what they need to succeed. That perspective will be invaluable in this role.”

Redmile said, “The strength of Michelin has always been rooted in the strength of our talented teams. I’ve had the privilege of working alongside employees across our operations, and they are at the heart of what drives us forward. I want to build on that foundation and help our people continue to learn, innovate and shape what comes next for our industry.”

Apollo Tyres, one of the leading manufacturers of tyres in India, has reported its financial results for Q2 FY2027 and H1 FY2027, alongside announcing the appointment of Ravi Kumar Shingari as its new Chief Financial Officer, effective 4 November 2026.

In his new role, Shingari will be reporting directly to Vice-Chairman and Managing Director Neeraj Kanwar. He joined Apollo Tyres in 2018 as Group Head of Finance and subsequently managed functions across budgeting, accounts, investor relations, and legal affairs, following a 16-year tenure at KPMG as Partner in Tax and Regulatory.

The company announced that its consolidated revenue from operations for Q2 grew by 17 percent YoY to INR 79.68 billion, compared to INR 68.31 billion in the corresponding period of the previous fiscal year.

Operating profit for the quarter stood at INR 8.55 billion, while net profit grew 13 percent to INR 2.92 billion, as against INR 2.58 billion in Q2 FY26. The net profit figures include an estimated pre-tax restructuring cost of INR 260 million recorded as an exceptional item.

For H1 FY2027, revenue reached INR 153.66 billion, up 15 percent from INR 133.92 billion in H1 FY26, with operating profit closing at INR 17.23 billion and net profit at INR 6.41 billion.

Onkar Kanwar, Chairman, Apollo Tyres, said, "Growth across categories in India has been supported by our sustained rural expansion efforts and strategic association with cricket. In addition, the launch of new products in the commercial vehicle segment in India has strengthened performance during the past quarter. At the same time, geopolitical tensions in West Asia remain a headwind, resulting in elevated input costs and supply chain disruptions."

Also read: Apollo Tyres Appoints Abhineet Kothari As India Business Head For Vredestein

From advanced materials and compound development to intelligent production, testing, simulation and regulation, the global tyre technology community returns to Hannover on 2, 3 and 4 March 2027.

Tire Technology Expo will open its 27th edition next March across Halls 19, 20 and 21 at Deutsche Messe, Hannover. For tyre manufacturers, vehicle OEMs, material developers, production engineers, technical directors, researchers and regulatory specialists, it is one of the few dates in the calendar when the complete tyre development and manufacturing chain can be examined in one place.

That breadth is increasingly important. Tyre performance is being reshaped by changing vehicle architectures, tighter sustainability targets, evolving regulation and the growing role of data in development and production. Progress rarely depends on one isolated technology. It requires decisions across materials, design, process engineering, quality control, testing and the factory systems that connect them.

THE FULL PRODUCTION CHAIN, IN ONE VISIT

Across the three halls, the 2027 exhibition will present more than 240 technology and materials solutions. Visitors will be able to investigate raw and reinforcing materials, speciality chemicals, process oils and compound development alongside mixing, extrusion, calendering, tyre building, mould, curing and cutting technologies.

The show floor will also cover factory automation, handling and logistics, in-line measurement, X-ray inspection, uniformity and balancing, RFID, smart tyres, simulation software, lifecycle monitoring, recycling and homologation. It is a practical opportunity to assess how individual technologies perform within the wider production environment rather than viewing each stage in isolation.

A plant manager can move from dosing and mixing to material handling and process control. An R&D engineer can discuss compound properties, test methods, modelling and production feasibility during the same visit. Vehicle OEM teams can meet specialists in tyre behaviour, data acquisition, simulation and connected-tyre applications, as well as the companies responsible for turning those developments into repeatable industrial processes.

The 2027 exhibitor list is already bringing together major machinery, automation, materials and testing organisations. Confirmed names include VMI Group, HF Group, TROESTER, KraussMaffei Extrusion, Rockwell Automation and Siemens, together with ARLANXEO, Asahi Kasei, Evonik and Henkel. Testing and development expertise is represented by organisations including MTS and Applus IDIADA.

THE CONFERENCE: SUBSTANCE BEHIND THE INDUSTRY’S BIGGEST QUESTIONS

The 2027 speaker lineup is going to be released in the very near future, with the direction of the three-day Tire Technology Expo Conference already clear. The presentations will highlight the scientific, technical, business and regulatory contributions, with an emphasis on genuine insight, practical experience and application-led case studies rather than corporate presentations.

The highlighted subjects reflect the decisions now facing tyre manufacturers and their customers. They include sustainable manufacturing, circularity, retreading and material reuse; advanced and alternative materials; requirements linked to the Ecodesign for Sustainable Products Regulation, deforestation rules and homologation; tyre and road wear particles and the implications of Euro 7, including a specific focus on C3 tyres; virtual tyre development, testing, modelling and simulation; intelligent connected tyres, sensors and data applications; AI in R&D and manufacturing; supply-chain resilience; and tyre integration with electric, autonomous and software-defined vehicles.

The programme is being shaped with input from an advisory group that includes senior expertise from Continental, Michelin, Tyres Europe and the University of Twente. The conference is set to bring together more than 170 expert speakers and over 100 hours of presentations and panel discussions across three days, creating a concentrated forum for tyre makers, vehicle manufacturers, suppliers, regulators, research institutions and academia.

For delegates, its value goes beyond individual presentations. The format allows the technical and regulatory implications of a development to be tested against different viewpoints, often while the relevant materials, equipment and measurement technologies can be examined a few steps away on the exhibition floor. Delegate passes also include hospitality, private networking, access to the awards and post-event access to presentation materials. The programme and delegate registration will be released in due course.

DEVELOP SPECIALIST KNOWLEDGE THROUGH THE SHORT COURSES

Four specialist short courses will run during the event week, with the full 2027 programme and booking details to be announced. The established subject range spans tyre mechanics, mathematical modelling, regulations and reinforcement, with formats ranging from one to four days.

These courses are intended for professionals who need more depth than a conference session can provide. Previous programmes have taken participants through subjects such as tyre structure and compounding, grip and durability, finite-element and real-time modelling, tyre-road interaction, EU and UNECE regulatory frameworks, type approval, tyre labelling, reinforcement properties and fatigue testing.

For engineers, scientists, technical managers and regulatory teams, the courses provide a concentrated opportunity to strengthen knowledge that can be applied directly to current development and manufacturing work. They also offer a valuable common technical foundation for colleagues moving into new responsibilities or working across different parts of the tyre and vehicle industries.

RECOGNISING THE WORK MOVING THE INDUSTRY FORWARD

The Tire Technology International Awards for Innovation and Excellence will again place the industry’s strongest recent work under the spotlight. The 2027 awards cover 11 categories across environmental achievement, chemicals and compounding, materials, R&D, manufacturing, supplier performance, tyre concepts and finished products. Access to the ceremony is included with a visitor pass and takes place right after the networking drinks, giving the wider expo audience an opportunity to see which developments are setting the benchmark for the sector and to catch up with new and existing connections.

PLAN THE CONVERSATIONS THAT MATTER

Tire Technology Expo is built around practical progress. It is where a new material can be assessed against production requirements, a modelling approach can be discussed with vehicle and tyre specialists and an equipment investment can be examined with the engineers who will support its implementation.

The exhibition is open to tyre industry and related professionals, and visitor registration is now available. Conference delegate registration and short-course booking will open separately as the 2027 programmes are confirmed.