According to a research report, by 2026, TMPS penetration will up to 79% and 25.26 million units be installed from the installation 16.49 million units in 2019. China will be the main growth driver for the TPMS segment

 

Growing legal compulsions and focus on safety, comfort and fuel efficiency will drive demand for tyre pressure monitoring systems (TPMS), says Agneta Ronceret, EMEA TPMS Manager for OEM, truck and industrial markets at ATEQ.

ATEQ is the leader in supplying a wide range of TPMS activation tools for tyre workshops and assembly lines at auto manufacturing plants across the globe. ATEQ’s TPMS range covers simple TPMS triggering tools, TPMS reset tools, complete TPMS relearn tools and more advanced TPMS diagnostic and programming tools, which can either be used autonomously or in combination with an OEM scan tool.  The company’s TPMS decoding tool can trigger or activate sensors, receive TPMS sensor information and send the TPMS sensor information to the vehicle’s ECU. The TPMS sensor information collected by the TPMS decoding tool includes the pressure within the tyre, the temperature of the TPMS sensor, the wheel rotating speed, the TPMS sensor unique ID, the battery status of the TPMS sensor, and more.

TMPS legal requirement was introduced in 2008 after Firestone recalled more than 6.5 million vehicles due to tread separations. As per the first version of the Tread Act, from 2008, all passenger vehicles and light trucks with GVWR of 10,000 lbs and less should be equipped with a TPMS. Europe, in 2012, too formulated EU TPMS regulations to make to TPMS compulsory in all new passenger vehicles from November 2014.

As of now the European Union, the United States, South Korea and China have already made TPMS mandatory in the vehicles, while other countries such as Japan, Indonesia, India, the Philippines and Malaysia are in the process to introduce TMPS legislation in the respective markets soon.

“Many countries and auto companies have a vision of zero road accidents or casualties. Followed by the US and Europe, other major markets, such as China, which is the largest automotive market, have also made TMPS mandatory. Multiple companies are also voluntarily implementing TPMS in their vehicles to optimize safety, mileage, and comfort. These trends will drive the growth for the TMPS market,” Ronceret told Tyre Trends.

 

According to a research report, by 2026, TMPS penetration will up to 79% and 25.26 million units be installed from the installation 16.49 million units in 2019. China will be the main growth driver for the TPMS segment.

Ronceret was appointed to the position last year to tap growing demands of the OEM, Truck and Industrial segments for Europe, Middle East, Africa and Australia and New Zealand regions. “There are lots of new activities that are happening in the OEM, Truck and Industrial segments. We have different objects for different segments. As the market grows and technology changes, ATEQ will bring innovations to increase our presence in the OEM, Truck and Industrial markets,” Ronceret said.

Air inflation

Tyres are the only component of the vehicle that touches the road. From safety and comfort and mileage largely depend on the air inflation in the tyres. Generally, a tyre naturally loses 0.2 atmospheres (2.9 PSI) every three months, and a slow puncture precedes 85% of all tyre blasts. Inappropriate tyre cause to the instability of the vehicle, and less mileage and the total life of tyres.

According to a study, around 30% of underinflated tyres increase fuel consumption by 5%. NHTSA, US EPA and US GAO studies say that in the US alone the overall deterioration in fuel economy due to underinflated tyres is 3.3% and the average annual wasted fuel is between 1.2 and 2.8 billion gallons. Over 2 billion gallons of fuel are wasted in Europe annually due to underinflation, as per Bridgestone Europe. At the same time, tyre life reduces by 50% if it runs at 20% under-inflation.

A TPMS updates the driver on air pressure conditions of the tyres. Inside the tyre, behind the valve, sensors measure pressure and temperature all the time, and as soon as the tyre pressure starts to drop, the sensors begin omitting alert signals to the ECU. 

There are two types of TPMS sensors, direct and indirect. Using the TMPS inside the wheel, the direct TPMS sensor, mounted on the wheels or tyre, reports accurate data on tyre pressure to the ECU. The direct TPMS systems are used European, the US and Asian markets.

Based on the ABS sensors, the in-direct TPMS system analyses the acceleration of the tyre and if the dimension of the tyre changes, so will the acceleration of the tyres. The ABS sensors notice the changes in the dimension of tyres and indicate the same. “The direct the TPMS is more precise as it gives you real-time data on pressure, whereas the ABS sensors only give you an indication,” said Ronceret.

Today the company operates in the three TMPS segments- Workshop Tools, Truck TPMS and Industrial TPMS.

ATEQ workshop tools are used in OEM garages and vehicle workshops for activating, diagnosing, programming and fitting TPMS valves and sensors. The workshop tools also help to replace the broken sensors in the tyre and even programme the sensors. “There are companies that make universal sensors, so ATEQ TPMS tools help to write programmes for those sensors. The tools also help to pair the sensors with the ECU,” explained Ronceret.

Revenue-wise, the workshop tool is segment is the largest business for ATEQ.  “For the workshop tools, we have to be evolutive. A bigger challenge for the company is to have the compatible tools for the existing and future vehicles,” said Ronceret.

The industrial tools, fitted at one place, are used in the vehicle production line to check whether tyres are accurately inflated before mounting on the vehicles.

ATEQ has a comprehensive range of TPMS control equipment for small to large manufacturing. On the assembly lines, its TPMS test antennas are key for the installation of TPMS sensors and the pairing of TPMS sensors with the vehicle’s ECU. The company supplies customized TPMS tools test TPMS sensors on OEM light vehicle and truck production lines, as well as wheel and tyre assembly lines, laboratories and test benches all over the world.

In trucks, a 10 PSI, less air pressure increases, rolling resistance by 2%, while industry surveys show that consistent proper tyre inflation in truck tyres would increase fleet wear by 17%.  Today, understanding the importance of the right tyre pressure, now many fleet companies have installed TPMS systems to improve the total cost of ownership. For the European truck industry, the company provides the ATEQ VT TRUCK tool, which checks tyre pressure and sensor batteries to prevent under-inflation and reduce vehicle downtime due to tyre blowouts. The tool is compatible with most European truck and bus TPMS sensors and benefits from a continually growing vehicle coverage, thanks to frequent database updates,

The company gets data from all OEMs to make sure it is updated with the times. “We have all data since we work with OEMs since the integration at the production lines to the workshops. It is also essential of them to we can serve them all the times.” The company maintains confidentiality on the secured data. The tools deal with the information collected from sensors but do not store them.

 

Continental's leadership in reducing tyre wear is fundamentally driven by its pioneering research into how particles are generated. A pivotal element of this strategy is the recently concluded OLRAP project, a collaboration with the Technical University of Braunschweig that broke new ground in real-world particle analysis. The research team engineered a complex experimental vehicle, outfitting it with a custom vacuum system and sensitive particle sensors. This innovative setup enabled the real-time collection and analysis of airborne particles directly at their source – the rolling tyre – under actual driving conditions. The resulting data, which for the first time correlates specific driving dynamics like aggressive acceleration and hard cornering with particle emissions, provides an unprecedented understanding of wear patterns.

This deep, data-driven insight is what directly fuels Continental's product development. By knowing precisely how and when wear occurs, engineers can make targeted optimisations to tread patterns and rubber compounds. The objective is to systematically design tyres that shed less material, thereby directly reducing their environmental footprint from abrasion. This development process rigorously maintains the critical safety and performance standards that drivers demand.

The tangible success of this research-to-development pipeline is confirmed by independent analysis, which shows Continental tyres abrade 11 percent less material than the competitor average. Furthermore, this proactive research and development strategically prepares the company for upcoming regulations like the Euro 7 standard, which will impose limits on tyre wear emissions. Beyond its own laboratories, Continental extends this commitment through cross-industry efforts, co-chairing the Tire Industry Project and contributing to public initiatives aimed at capturing tyre particles from road runoff. Through this integrated approach, Continental is leveraging fundamental scientific discovery to create more sustainable mobility solutions.

In a significant step for connected mobility in India, JK Tyre & Industries has launched the nation's first Embedded Smart Tyres designed for passenger vehicles. This innovation, developed entirely in-house and produced at their Banmore plant in Madhya Pradesh, moves tyre technology beyond a passive component to an active, intelligent part of the vehicle. This launch reinforces the company's commitment to the 'Make in India' initiative and establishes a new benchmark for intelligent driving.

The core of this advancement lies in sophisticated sensors that are built directly into the tyre itself during the manufacturing process. Unlike external systems, these embedded sensors provide continuous, real-time monitoring of vital operational data. They track crucial metrics such as internal air pressure, temperature and can even detect potential air leaks. This constant stream of information translates into actionable insights for the driver, which substantially boosts vehicle safety, optimises performance and increases overall driving efficiency.

This new product builds upon JK Tyre's established history with its 'SMART Tyre' technology, an earlier industry-first that integrated Tyre Pressure Monitoring Systems with cloud analytics. The latest embedded version represents a natural evolution, further solidifying the company's role as a pioneer in the mobility sector. Beyond the primary safety benefits, these smart tyres are also engineered to deliver practical advantages for consumers, including a longer tread life and improved fuel economy, which also contributes to a lower environmental impact. Initially, these next-generation tyres will be offered in the aftermarket in sizes from 14 to 17 inches, making this advanced technology accessible to a broad range of car owners.

Dr Raghupati Singhania, Chairman & Managing Director, JK Tyre & Industries Ltd., said, “The launch of our Embedded Smart Tyres marks a defining milestone in JK Tyre’s innovation journey. Backed by our strong R&D and manufacturing capabilities, this achievement reflects our commitment to advancing technology-driven mobility. By integrating intelligence at the very core of performance, we are transforming the way India drives, making mobility smarter, safer and more sustainable. This development is a testament to JK Tyre’s unwavering focus on technological excellence and our vision to lead the future of connected mobility.”

JK Tyre & Industries Ltd on Monday inaugurated India’s first precision tyre buffing and grinding machine for wet grip testing of worn tyres at the National Automotive Test Tracks (NATRAX) facility in Pithampur, Madhya Pradesh, marking a significant step towards advancing road safety and self-reliance in tyre performance evaluation.

The inauguration ceremony was attended by Dr Raghupati Singhania, Chairman and Managing Director of JK Tyre, and Dr. Manish Jaiswal, Director of NATRAX, along with senior officials from both organisations.

The newly installed equipment complies with ECE R117 regulations, which evaluate a tyre’s wet braking performance when worn to the legal tread depth limit of 1.6 mm. The system allows precise preparation of worn tyre samples across C1 (passenger car), C2 (light commercial) and C3 (heavy truck/bus) categories, enabling comprehensive Wet Grip on Worn Tyre (WGWT) testing at NATRAX.

“With the inauguration of the Precision Tyre Buffing and Grinding Machine (Wet Grip on Worn Tyre) at NATRAX, JK Tyre has taken yet another step forward in advancing tyre testing and safety innovation in India,” said Dr. Raghupati Singhania, Chairman and Managing Director, JK Tyre & Industries. “It reflects our unwavering commitment to innovation, technology leadership, and enhancing vehicular safety through modern engineering and contribution to build world-class testing infrastructure.”

The installation strengthens JK Tyre’s existing testing ecosystem, supporting both homologation and new product development. The company has been associated with NATRAX since 2017, utilising its advanced facilities for vehicle-level testing such as handling, braking, wet grip and noise evaluation.

JK Tyre has also invested in dedicated infrastructure at the NATRAX campus, including two workshops, a skilled technical team, and advanced testing equipment such as a skid trailer, steering robot and noise measurement systems, supported by a fleet of test vehicles.

The global tyre industry is in the midst of its greatest upheaval since the pneumatic tyre – driven by rapid digital transformation. Siemens, the German global technology company, is leading this revolution, quietly redefining how tyres are designed, manufactured and maintained worldwide.

In a sprawling industrial complex outside Nuremberg, Peter Haan, Head of Global VM Tire, Siemens, brings the enthusiasm of someone who has witnessed an industry’s complete metamorphosis to the oversight of Siemens’ global tyre operations. Recently, Haan outlined the company’s comprehensive strategy for modernising tyre production – addressing the price-sensitive manufacturers of Asia as well as the sustainability-focused plants of Europe.

“Digital transformation didn’t start yesterday, and it didn’t even start during the pandemic,” Haan explains, dispelling common misconceptions about the industry’s technological evolution. “We’ve been working on this for more than 10 years now. We had digital twins a decade ago, which might surprise people who think this is cutting-edge technology.”

The Industrial Metaverse Revolution

The foundation of Siemens’ approach lies in what Haan calls ‘digitalisation for design’ – the creation of what the company now terms the industrial metaverse. This comprehensive digital simulation integrates machines, programmes and entire production processes. It represents years of focused development and has achieved what Haan considers ‘very good status with our integrated approach’.

Haan’s descriptions of recent projects clarify these implications. “We are just building a new plant in Singapore and expanding an existing plant in Germany” he reports. Due to confidentiality agreements, he cannot display the complete digital representation on his computer. Instead of seeing only lines and geometric shapes that require imagination to translate into real machines, one can now observe photorealistic models: virtual people moving, machinery operating and materials progressing through the production process.

This industrial metaverse requires immense computing power, necessitating a close partnership between Siemens and Nvidia. While most consumers know Nvidia for its gaming graphics cards, the company also produces high-end simulation capabilities that enable Siemens and Siemens customers to run simulations in real time with an absolute realistic look and feel.

A second key pillar is digitalisation for operations, achieved through advanced planning and scheduling systems. Tyre manufacturing today exists in a dynamic environment, where customer demands can change daily, a stark contrast to the older, more predictable monthly or quarterly cycles.

“Today, a customer might want to capture one market segment. Tomorrow, they might pivot to electric vehicle tyres. Next week, they could have entirely different ideas based on market conditions,” Haan explains. “Traditional planning systems simply cannot handle this level of flexibility.”

The solution involves Manufacturing Operations Management (MOM) systems that provide immediate responsiveness to market changes. Siemens has successfully implemented this approach across multiple regions, including a completely new greenfield facility in Chennai, which was designed from the ground up using digital operations principles.

Modernising Legacy Infrastructure

The process of implementing digitalisation becomes more challenging when accounting for the hundreds of tyre manufacturing plants worldwide, many of which are equipped with machinery that has decades of operational history. Nevertheless, Siemens has crafted a methodical approach to address these ageing systems.

“This is actually easier to answer than most people expect, though the implementation requires careful planning,” Haan notes. The process begins with laser scanning systems that create high-precision three-dimensional digital representations of entire facilities, mapping every machine location, material flow and worker movement pattern.

This laser-generated data becomes the foundation for plant simulation software that models current operations. “The next crucial step is comparing our simulation results with actual reality to ensure accuracy,” Haan explains. “Initially, no improvement is achieved – we’re simply creating a digital mirror of existing operations.”

Once accurate digital representations exist, optimisation can begin in the virtual environment first. Companies can simulate workflow changes, test automated guided vehicle implementations and identify bottlenecks without disrupting actual production.

To add intelligence to existing machinery, Siemens utilises edge computing devices. “Our SIMATIC IPC127E, for instance, can connect to all existing automation systems, even equipment that’s 30 years old,” Haan says. “We can interface with legacy automations systems from Siemens and any supplier, thus adding intelligence to old machines”

The retrofit approach varies based on existing capabilities. Some situations require minimal hardware changes, while others demand comprehensive replacements of the automation system. “If you have a state-of-the-art automation system, you might need no new hardware at all – just download additional functionality,” Haan explains.

Digital Twins And Real-Time Optimisation

The concept of digital twins running parallel to actual production represents one of Siemens’ most sophisticated technological achievements. These systems utilise edge computing to operate what Haan calls ‘live twins’ that mirror physical machine behaviour in real-time.

Tyre curing provides a compelling example of this technology’s potential. “The temperature inside the bladder during the curing process is challenging to measure directly, especially with traditional rubber bladders,” Haan explains. “But with our digital twin technology, we have virtual sensors so sophisticated that you can specify any point in the bladder, and our system can compute and calculate the exact temperature at that location.”

This capability bridges the gap between simulation and the real world, providing measurement data that is unobtainable through physical sensors. The digital twin processes information such as product geometry, material compression due to steam or water and flow directions influenced by the physical layout. With this, precise optimisation of curing parameters becomes achievable.

“The simulation can then influence real curing behaviour, making the process more accurate and potentially reducing curing time,” Haan notes. For electric curing systems, this precision enables targeted heating adjustments, such as applying additional heat to tyre edges while maintaining optimal internal temperatures.

Regional Market Dynamics

The global tyre industry’s digital transformation unfolds differently across regions, requiring distinct strategies tailored to local market conditions and regulatory environments. These differences significantly impact how Siemens approaches each market.

In China and the broader Asia-Pacific region, price sensitivity dominates decision-making processes. “Customers are extremely price-sensitive, focusing primarily on capital expenditure (CAPEX). Operational expenditure (OPEX) considerations often aren’t in scope initially,” Haan explains. “We have to continually focus about lifecycle costs versus initial purchase prices.”

This dynamic creates challenges for Siemens’ solutions. When comparing automated guided vehicles, for example, Chinese manufacturers often prefer locally-produced systems based on proprietary electronics that appear cheaper initially. Siemens takes a different approach, building AGVs exclusively with industrial automation components – standard PLCs, drives, motors and HMIs.

“Initially, our solution costs more compared to a proprietary electronics-based AGV – we simply cannot compete on initial price with local suppliers,” Haan acknowledges. “However, when you consider lifecycle costs, our approach becomes significantly less expensive.”

The advantage becomes apparent during maintenance scenarios. When a motor fails in a Siemens system, customers can replace it with standard components they likely maintain in inventory for other machinery. Proprietary systems require specific spare parts from original manufacturers, assuming availability and reasonable delivery times.

European Cybersecurity And Workforce Challenges

Europe presents entirely different challenges, beginning with the Cyber Resilience Act (CRA) that will fundamentally reshape the automation landscape starting in 2026. This legislation mandates that all industrial automation products meet specific cybersecurity requirements, with significant implications for existing equipment.

“The European Commission has decided that industrial production and critical infrastructure must be secured against cyber-attacks,” Haan explains. “Given that Europe is effectively at war and cyber attacks are a daily occurrence, this is not just theoretical.”

Siemens is proactively addressing this transition by working with customers to review their equipment bills of materials and provide updated specifications for compliant replacements. This affects both new installations and retrofits, as any significant upgrade must meet new security requirements.

Europe also faces demographic challenges that influence automation requirements. “We have an ageing society with fewer people than countries like India or China, and we’re experiencing a shortage of experienced workers and technical experts,” Haan explains. “This means our products must be simple to use, and machines of our customers must be operated simply.”

European manufacturers also demand continuous operation capabilities. “24/7/365 operation – production cannot be interrupted by unexpected downtime. Predictive maintenance isn’t just nice to have; it’s urgently necessary,” Haan emphasises. “When we work with major German tyre manufacturers, predictive maintenance is included from the beginning. If anyone offered a mixing line without predictive maintenance, they wouldn’t even be considered.”

Artificial Intelligence In Manufacturing

The application of artificial intelligence (AI) in tyre manufacturing has moved from experimental to essential, particularly in areas traditionally requiring human intervention. Visual inspection represents the most obvious opportunity for AI implementation.

“Even in highly automated plants – and I’ve visited completely automated facilities that are quite impressive – you still typically see 20 people doing visual inspection of finished tyres,” Haan observes. “But here’s the fundamental problem: after inspecting 100 tyres, human consistency inevitably declines. We’re not machines – our attention wavers, we get tired, we make mistakes.”

Siemens is collaborating with companies to develop AI-powered inspection systems that integrate high-quality optical equipment with sophisticated pattern recognition algorithms. “The AI must determine whether there’s a fault, what type of fault it is – is it a bubble, is it incorrect wire placement, is it a surface imperfection?” Haan explains.

When discussing accuracy expectations with plant managers, Haan maintains realistic perspectives. “When asked whether the machine recognises 100 percent of failures, I’m honest – no, not 100 percent. But I can say that it recognises defects more accurately and consistently than human beings.”

AI applications extend beyond inspection into production processes themselves. In curing operations, Siemens utilises AI through digital twin technology that operates in parallel with physical equipment. “We measure all incoming variables – electric power consumption, steam pressure, external temperature, internal conditions – and feed this information to our digital life twin running on edge computing devices,” Haan explains.

Using computational fluid dynamics simulations, the system accurately understands how heat behaves throughout the curing process. Real-time comparison between simulation predictions and actual conditions enables continuous optimisation. “For electric curing systems, we can even create different temperature zones – applying more heat to tyre edges while maintaining optimal internal temperatures.,” says Haan.

Sustainability Beyond Green Materials

Sustainability in tyre manufacturing encompasses far more than renewable raw materials, extending through entire product lifecycles from manufacturing to end-of-life processing. Siemens has developed comprehensive approaches to address these challenges.

The company’s ‘SiGREEN’ system calculates complete product-related carbon footprints using standardised communication protocols that include all supplier contributions. “Most companies, when asked about the carbon footprint of a specific tyre, can’t provide accurate data,” Haan notes. “Approximately three-quarters of a tyre’s carbon footprint doesn’t come from the manufacturing plant. It comes from purchased materials and the energy used to produce them.”

This complexity requires sophisticated tracking capabilities. “These complex calculations change dynamically as supply chains shift towards geographically closer sourcing locations,” Haan explains. “Our system links to the bill of materials for each product, tracking exactly what compounds are used in tyre treads versus sidewalls and maintaining complete supply chain traceability.”

This transparency is becoming crucial for business relationships. “Previously, negotiations between tyre manufacturers and automotive companies focused primarily on price. Now we have a new critical component: carbon footprint,” Haan says. Automotive manufacturers face government-mandated carbon limits with significant penalties for non-compliance, making tyre carbon footprints a competitive differentiator.

Tyre recycling represents another sustainability frontier where Siemens provides technological solutions. The company collaborates with several organisations that are advancing pyrolysis technology for tyre breakdown, including joint ventures involving major tyre manufacturers that utilise our completely web-based process control system SIMATIC PCS neo.

“Pyrolysis plants are sophisticated chemical operations requiring precise parameter control,” Haan explains. “You cannot simply shut down a pyrolysis plant during lunch breaks like some other manufacturing processes. These systems require continuous operation with carefully managed temperature, pressure and material feed rates.”

Siemens also supports ultra-high-pressure water jet technology for tyre breakdown, which uses high-pressure water streams to separate tyre components for direct reuse. “This technology requires precise PLC control to manage water pressure, flow rates and separation processes,” Haan notes.

Innovative Equipment Design

Siemens has identified fundamental inefficiencies in traditional tyre manufacturing equipment and developed innovative solutions to address them. Curing presses exemplify this approach effectively.

Standard curing presses typically feature large HMI screens for operator interaction, but actual utilisation analysis reveals these expensive displays are used less than five percent of operating time. “These screens are costly to build and maintain, especially in curing environments with high temperatures and corrosive gases that damage electronic displays. Yet they sit unused most of the time,” Haan explains.

Siemens’ solution eliminates local HMI screens entirely, replacing them with mobile devices, such as tablets, connected to centralised SCADA systems running WinCC software. Haan says, “All screens for all curing presses across a plant are hosted on centralised servers. When an operator needs to interact with a specific curing press, they log into that machine through their mobile device,” says Haan.

This approach provides identical functionality while dramatically reducing costs and improving reliability. “If a plant has 10 operators, providing 10 tablets costs far less than installing individual screens at each curing press. The mobile devices also have much higher utilisation rates and can be used anywhere in the facility,” adds Haan. Electrical curing technology represents another significant innovation thanks to Siemens’ modular ‘e-Starter’ systems, which control heating circuits in electric curing presses. The modular design accommodates various press configurations while providing automatic protection against electrical faults commonly found in high-temperature environments.

“In steel moulds at high temperatures, insulation can fail, creating dangerous grounding or short circuit conditions. Our system recognises these automatically and sends immediate alerts to operators,” Haan explains. The flexibility allows manufacturers to configure systems precisely for their needs, whether they require eight heating segments or 20 or more.

Advanced Fleet Management

Material handling and logistics automation have evolved significantly. Siemens’ offerings include SIMOVE AGV technology along with comprehensive fleet management solutions, featuring free navigation capabilities that offer greater operational flexibility compared to traditional guided vehicle systems.

The company’s unique approach to AGV fleet management centres on the SIMOVE platform and fleet manager software. “We use only industrial automation components in our AGVs – standard PLCs, drives, motors and HMIs that customers already understand and maintain,” Haan explains.

The fleet management system supports VDA 5050, a standardised communication protocol enabling AGVs from different manufacturers to communicate with each other and central management systems. “Think of it like Profinet for industrial automation – a common communication standard,” Haan says.

Siemens can integrate proprietary protocols from various suppliers, with the fleet manager currently supporting over 20 different AGV communication protocols. This capability gives customers the flexibility to operate mixed AGV fleets while maintaining centralised control.

“The system can control both real-world operations and simulations. If you have a digital simulation of your plant, our fleet manager can demonstrate how AGVs will operate before physical implementation,” Haan notes.

Predictive Maintenance Evolution

Siemens’ Senseye predictive maintenance system distinguishes itself through two key advantages over competitor offerings. First, the system utilises data from standard automation components that generate extensive operational information automatically.

“All drives, all PLCs generate extensive operational data automatically. You can get current consumption, torque output, operating temperatures and many other parameters directly from standard components,” Haan explains. “Just by analysing this standard information, we can predict when machines are at risk.”

Pattern recognition enables early identification of developing problems. Unexpected changes in current consumption patterns might indicate bearing wear or other mechanical issues weeks before actual failure occurs.

The second advantage involves Senseye’s internet-based architecture, which, with customer permission, compares similar machines across Siemens’ global installed base by connecting to standard databases. “This means customers benefit not just from learning about their own machines but from patterns identified across all connected machines worldwide,” Haan says.

This global learning capability creates powerful network effects. When Siemens identifies a failure pattern in one facility, that knowledge immediately becomes available to prevent similar failures in other locations using comparable equipment.

Industry Consolidation And Future Outlook

The global tyre industry is experiencing dramatic structural changes, particularly evident in China, where consolidation has accelerated significantly. “Five years ago, there were approximately 500 tyre manufacturers in China. Now we’re down to fewer than 300,” Haan reports.

This consolidation reflects both market forces and deliberate government policies that promote industry efficiency and environmental performance. “China’s manufacturing policy demands higher technology adoption, better environmental performance and reduced energy consumption,” says Haan. Export challenges compound these pressures, making it difficult for smaller manufacturers to achieve the scale necessary for survival. Government support actively encourages consolidation towards larger, more technologically advanced companies capable of global competition.

Siemens is positioning itself for these changes through what Haan calls ‘glocalisation’ – the company’s new plant that is planned in Singapore reflects this approach. “We’ll see increasingly region-specific trends that require local adaptation while maintaining global technological standards,” adds Haan. The future belongs to companies embracing comprehensive digital transformation rather than piecemeal automation upgrades. “Companies must understand lifecycle costs rather than focusing solely on initial purchase prices. They need to integrate sustainability metrics into operations from the beginning, not as an afterthought,” Haan emphasises.

Most importantly, successful manufacturers will be those capable of rapid adaptation to changing market demands through flexible, digitally-enabled production systems. “The technology exists today to achieve this flexibility – the question is which companies will have the vision and commitment to implement it comprehensively,” says Haan. As Haan concludes: “The tyre industry’s digital transformation is no longer a future possibility – it’s happening now. Companies that delay this transition risk being left behind in an increasingly competitive and regulated global marketplace.”