There couldn’t be any industry that isn’t implementing, or at least knowing about, automation. And if there’s actually one, then it has probably been living under a rock. The tyre industry has already opened its doors to automation, and this helps make tyre manufacturing more sophisticated and reliable. The tyre manufacturing process itself has been experiencing constant changes – from different tyre sizes and constructions to targeting less usage of energy. Automation must be on every tyre company’s to-do list, if it hasn’t adopted it already. Don Heelis, Sales Manager, Cimcorp, gave Tyre Trends more insights on the different aspects of automation in the tyre industry and its absolute requirement, when we met him at the Tire Technology Expo 2022 in Hannover, Germany. Read on…

The philosophy of tyre manufacturing has changed dramatically. A part of the change in that philosophy relates to automation implementation in the tyre manufacturing process. However, we also find more technical perspectives being adopted and taken into account at new, modern tyre factories today.

This technical perspective can be considered to be coming from a few different areas, one of them certainly being from the actual production part of the tyre factory. Therefore, with production machinery, mixers, extruders and tyre building machines, the level of technology being implemented in these processes is increasing. Moreover, these processes are getting more sophisticated.

The other aspect of this is integrating the production across all the different areas (another factor for the dramatic change in the modern tyre factory). In the past, the different areas of production were not necessarily well connected. However, today we see them getting connected a lot more – and this is being driven and enabled by technology.

This is where companies like Cimcorp come in – who happen to provide material handling and automation technology so that different tyre manufacturing processes are better integrated.

Explaining this, Don Heelis, Sales Manager, Cimcorp, said, “When you produce your work in process, what you’re producing is in synchronisation with what’s being produced in other areas of the factory. This helps minimise the work in process and have a manufacturing process that’s more efficient.”

Going the modular way
But how does one integrate different machines and processes in the plant with all the different machines and manufacturing processes involved? Heelis let us in on this.

“The trick is to implement the automation and connectivity in a modular way,” he revealed and went on, “That way, the connectivity is physical and mechanical but involves software as well. Thus, we take an approach where the modules are flexible and can connect to various inputs and outputs; however, the module is in itself standardised. Hence, the modules can work for different factories – only the interconnection needs to be flexible.”

The green tyre
While implementing automation, one, of course, would want to implement it where they get the biggest value. “Traditionally, that has been in the palletising area – in managing and handling the finished product. Basically, palletising, storing and retrieving the finished product,” Heelis informed us and continued, “This is where everyone has traditionally looked in the past. However, a lot of focus has been put on the green tyre area in the past 10 years. That includes green tyre handling, storage and retrieval and its automatic delivery to the curing process.”

A green tyre is work in process – simply put, a tyre that has not been cured. “A green tyre is made up of a number of components. It’s built on a tyre-building machine,” Heelis further told us. “Once a green tyre is built, it is buffered, followed by being cured – and automation machines are required in order to do this. Hence, this is a key element of the modern tyre factory.”

He added, “This has been an area of key focus where productivity and simplicity can be gained. In fact, the whole process can be done with less plant floor space. Ultimately, factories that want to be competitive have to implement automation technologies in that area.”

Increased efficiency
There are many brownfield factories out there that have to modernise and be viable for the future. One of the key areas that they need to modernise and automate in is green tyre handling. Heelis asserted, “By having an automated storage and retrieval system, one can track and trace all of the work in process. Plus, one is able to store in a manner that maximises the quality of the green tyres. And then, one can deliver them from the storage system to the curing process in a very systematic and accurate way. This way, when a particular green tyre is needed in the curing area, it can be delivered there in the appropriate amount of time.”

“In this methodology, when the green tyre arrives at curing, it is at that point in time when it is needed, and the production does not have to stop,” Heelis further shared. “If this can be achieved, then the curing process can be run more efficiently; the efficiency can go from 80 percent to over 95 percent. In theory, one can increase the output of their factory by 10 percent. In such a case, one can imagine how many tyres can be produced in a factory by following this methodology.”

Automation – its role during the pandemic and inflation
While automation tends to bring in efficiency, how have companies managed to keep up their competence and productivity during the thorny period of the Covid pandemic? The pandemic has definitely brought some insights to the tyre industry from a management point of view, like it did to many other sectors. According to Heelis, automation has come to the rescue of the tyre industry in the pandemic as well.

“One important thing that the industry learnt from the pandemic was that it has a risk to its ability to produce products,” he mentioned and went on, “The absence of automation will make any company in the industry highly dependent on the labour force, which might not be available to keep the production going. On the other hand, with automated processes, a company is less at risk to events like a pandemic.”

Another issue we are dealing with right now in the global economy is inflation. Inflation equals to costs going up – from the cost of materials to the cost of labour. “Nonetheless, a company can mitigate some of the impacts of inflation if it has embraced automation. In fact, the ones who automated their brownfield factories three to four years ago are in a much better position today than their competitors who had not,” Heelis pointed out and went on, “This is because the former can mitigate some of the inflation costs, is less dependent on the workforce and is able to produce better-quality products – and at a higher level of efficiency at that. We know that there is a tremendous shortage of people in the workforce in the US right now. Therefore, automated companies have a significant competitive advantage.”

From the tyre industry’s challenges due to the pandemic and inflation, we turned to the challenges Cimcorp itself faces on the commercial side. Heelis responded that, commercially, the current challenge for them is being a low-cost, high-quality producer – which one has to be in order to compete in the market. “Furthering this challenge is how we become a low-cost, high-quality producer and stay that way. And from our perspective, the way to get there is through innovation and technology,” he stated.

Automation in the Asian tyre industry
CIMCORP opened up an office in India roughly three years ago. With its presence in the country and Asia, Heelis told us that the tyre companies in Asia are no stranger to automation and are implementing it. “As a move forward, the mentality is that if you want to be a world-class manufacturer and build a new factory, then you build the factory with automation. And this is a global perspective,” Heelis asserted.

Cimcorp’s customers in Asia range from traditional tyre manufacturers to new manufacturing entrants in the industry, so it’s a mix. Throwing further light on this, Heelis said, “We all know the traditional manufacturers like Bridgestone, Michelin, Goodyear, Continental and more. But beyond these, there are new companies emerging. And these new companies have an advantage in some ways because they are not constrained by the old ways of thinking. They are forward thinking, with a clearer mindset to do things in the current environment – the environment of automation and technology.”

“Moreover, the manufacturers who don’t invest in automation, and try to run the company with practices that were developed in the 1960 and 70s, will not be able to survive or compete,” he further added. “Their market will eventually consider them to be non-competitive, non-global and unable to produce the quality expected of them.”

Cimcorp has plans for India as well. “Our strategy is to continue to grow our business in India with the domestic tyre manufacturers, and we have been successful at that,” Heelis shared and went on, “When I say domestic, that goes for manufacturing facilities within India, from Apollo Tyres to MRF to JK Tyre to Goodyear to Michelin. Thus, we plan to continue to build our business with those factories and customers from an automation perspective, and then from a full customer service point of view.”

The other aspect comes to brownfield factories. Heelis averred, “With brownfield factories, whether in North America or Asia, the cost of automation is the same; there may be different payback scenarios between the two. However, it stands true that no matter where a company is present in the world, if it is operating a brownfield factory, then it needs a strategy to modernise. And the strategy to modernise is based on implementing automation.”

Automation in brownfield factories – what will it take?
The strategy to modernise when automating a brownfield factory is especially challenging in an already existing system. Therefore, when automating a brownfield factory, one of the most important considerations is to not interrupt their day-to-day production, Heelis cited. He mentioned that the factory has to continue making its certain number of tyres each day. Hence, a strategy that enables the factory to do that is needed – while concurrently implementing automation there.

“Besides, when you implement automation, you have to be able to do it in a standardised way,” Heelis further enlightened and continued, “This can be done with the help of flexible automation modules that can work in a lot of different scenarios. Therefore, you can deal with different brownfield factories depending just on how you arrange your automation modules. Thus, you can come up with a custom solution for every different brownfield factory out there with the help of a modular approach and on the basis of how you connect those automation modules together.”

Service provided
From providing standard modular systems to hardware to software, Cimcorp strategically has a service aspect to its business – Success Services. Therefore, the approach from its service side is to enable its customers to be as successful as possible.

“That could be achieved by providing a 24/7 support. So if the customers contact us due to an issue they are facing in the solutions provided by us, we are available at any time of the day or night to support them,” Heelis revealed and added, “We can do it remotely. In fact, as technologies emerge further, we’ll see how we can do this more remotely with virtual techniques. Here, their serviceperson could be using special tools, which enables our people (who are remote) to actually be in virtual situations in our customers’ plants. In such wise, we can be more responsive and be as if we are in place in real-time in order to provide a service.”

Tyre warehouse automation or manual operation – making the choice
Nevertheless, Cimcorp does not just stop at its 24/7 services or providing its automation solutions for tyre manufacturing processes. It goes beyond that – to the finished product warehouses. However, interestingly, that depends to a degree on which part of the world the automation is needed in; while some areas will need automation that is well advanced, some areas will use a more manual operation.

Heelis explained, “There are some key factors that determine whether the facility/area in question needs to be automated or not. For example, the cost of real estate. If it’s a manual operation, then that typically involves a very large warehouse, say around 100,000 sq mt.”

“For automating, on the other hand, you require lands that are much smaller,” Heelis further highlighted. “For instance, land is very expensive in Japan. Thus, one wouldn’t want a very big footprint warehouse over there. Which means, you go vertical wherever land is expensive.”

“On the flip side, land is very cheap in some areas and inexpensive to build the generic building (like in some areas of the US). So there is less incentive to go vertical with automation there,” he added. “But there might be other factors that could dominate.”

Choosing automation over manual operation – why?
While some main factors do influence the decision if a warehouse is going to be a fully automated one or a semi-manual one, an automated one is always preferred. For clear reasons.

“The benefit of an automated warehouse is that everything is extremely well controlled,” Heelis informed. “What’s more, you have complete control of your product – you know exactly where it is, how much of it you have and you can get on-demand access.”

“As for a semi-manual warehouse, there are fork trucks, people moving things around and putting them in different storage locations,” Heelis further clarified. “This process is much more manual, involves a lot more interaction and is time consuming. Therefore, you have much less control over the process.”

Automation – a need not to be confused as a luxury
The automotive industry has been one of the earliest industries to adopt automation. So it’s high time that tyres, an integral component of any vehicle, did so too. It’s clear that automation, today, is not a luxury but a need. No company can afford to not have it. No tyre company must be limited to older technologies, and they must invest in automation for the long term. This would not just help tyre manufacturers meet their customers’ demands without any delay, but also help modernise the industry with the world’s rapidly changing technologies.

Al Salem Transportation & Tourism Co. (Al Salem) is reaping the benefits of Goodyear’s CheckPoint tyre monitoring technology system, which was implemented in its Dammam depot. This is a first for passenger transport companies in Saudi Arabia and builds upon the existing partnership between Al Salem Transportation & Tourism Co. (Al Salem), Goodyear and its official Saudi distributor, Al Rashed Tires.

Goodyear CheckPoint is a connected, yard-based drive-over tyre inspection system that provides fleet managers with useful information by reading vehicle data and tyre condition. Tyre pressure and tread depth examinations are time-consuming tasks that may be completed in seconds by Goodyear CheckPoint's automated system.

The system provides the ability to access data through user-friendly reports and allows Al Salem to address all their operational needs related to tyres. This decision is consistent with Al Salem's commitment to using cutting-edge technology to achieve the greatest levels of safety and efficiency, as well as the Saudi Vision 2030 aim of boosting the quality and connectedness of transportation networks.

Mustafa Alsalem, Business Development Manager, Al Salem Transportation & Tourism Co, said, "At Al Salem, our mission is to provide safe and comfortable journeys for everyone in the Kingdom. We pride ourselves on working only with industry leaders to deliver premium safety and service levels. Partnering with a leading global tyre manufacturer like Goodyear, renowned for their premium tyres and innovative digital fleet solutions, is a testament to our commitment to this mission."

Yasser Meyer, CEO, Al Rashed Tires, said, “We have a proud legacy of supporting the development of Saudi Arabia's automotive industry. Leveraging our in-depth market knowledge, we are able to localise global tyre technology, like Goodyear’s CheckPoint monitoring solutions, to empower our valued partners like Al Salem in their achievement of business goals.”

Saban Gungor, General Manager, Goodyear Middle East & Africa, said, "As a preferred fleet mobility partner, Goodyear is dedicated to delivering not only high-quality tyres but also value-added mobility solutions, like the CheckPoint tyre monitoring, to our fleet customers. We are thrilled to support Al Salem on their digitalisation journey with the adoption of this technology, setting a new benchmark for safety and operational efficiency in the Kingdom."

Vittoria, a global leader in cycling tyres and accessories, has announced opening new state-of-the-art research and development centres known as VittoriaLabs. These facilities, located in Italy and Thailand, are designed to push the boundaries of cycling technology and performance.

The VittoriaLabs will focus on developing innovative tyre and accessory solutions that enhance rider performance, safety, and sustainability. The centres will leverage advanced testing equipment and cutting-edge research methodologies to analyse and optimise product design.

“Vittoria Labs will be the engine driving our ambitions for market leadership in innovation in a future we are already shaping,” says Stijn Vriends, Chairman and CEO of Vittoria. “By combining state-of-the-art indoor and outdoor testing facilities, we can push the limits of what’s possible in cycling tyres and accessories while keeping sustainability at the core of our innovations,” adds Vanessa ten Hoff, Chief Innovation & Marketing Officer of Vittoria.

Vittoria’s investment in these facilities underscores the company’s commitment to innovation and its dedication to providing cyclists with the best possible products. By combining advanced technology with real-world testing, Vittoria aims to deliver products that meet the evolving needs of cyclists worldwide.

With the opening of the VittoriaLabs, Vittoria reinforces its position as a global leader in the cycling industry. The company’s focus on research and development, coupled with its passion for cycling, ensures that it will continue to drive innovation and set new standards in the years to come.

Webfleet, Bridgestone’s fleet management solution, has expanded its OEM.connect partner programme to include trailers. Schmitz Cargobull, a leading manufacturer of semi-trailers, is the first trailer manufacturer to join the programme.

This collaboration allows commercial fleet operators to seamlessly connect their Schmitz Cargobull trailers to the Webfleet platform through factory-fitted telematics. By eliminating the need for aftermarket hardware installations, fleet managers can save time and reduce costs.

“Trailers are the backbone of long-haul goods transportation, but managing a trailer fleet can be challenging,” says Taco van der Leij, Vice President, Webfleet Europe at Bridgestone Mobility Solutions.

“Making our proven Webfleet Trailer solution now easily accessible via OEM data, will help even more businesses with real-time data insights and actionable intelligence to maximise trailer performance. We are happy that we are collaborating with Schmitz Cargobull, offering our customers seamless integration with Europe’s leading semi-trailer manufacturer”.

Sören Danielsen, Manager, Strategy & Business Development at Schmitz Cargobull adds:  “With the TrailerConnect Data Management Center from Schmitz Cargobull, hauliers have full control over their data and can pass on selected data to third parties in an efficient way. By intelligently linking information on the vehicle, tour and order, more than just position and temperature data can be selected, processed and transmitted to third-party systems at the touch of a button in future. The TrailerConnect Data Management Center stands for connectivity and transparency. Everyone involved along the supply chain benefits from this.”

The integrated solution provides fleet operators with valuable insights into trailer performance, including location tracking, maintenance alerts and payload monitoring, said the tyre maker.

Bridgestone has joined hands with Astrobotic Technology to develop lunar rover tyres.

Bridgestone will leverage its 90 years of expertise in developing tyres for Astrobotic’s 24U CubeRover. These tyres will be designed to withstand the harsh lunar environment, including extreme temperatures and rugged terrain.

Bridgestone’s tyres will play a crucial role in enabling the rover to navigate the challenging lunar terrain.

The collaboration highlights the Japanese tyre maker’s commitment to expanding its reach into new and innovative areas of mobility. By partnering with Astrobotic, a leading space exploration company, Bridgestone aims to contribute to the advancement of lunar exploration and space technology.

The 24U CubeRover is a compact lunar rover designed to provide mobility, power and communication support for scientific instruments and payloads on the lunar surface.

As per Bridgestone, this partnership marks a significant milestone for the company as it expands its horizons beyond Earth and into the cosmos.