Apollo tyres limited are in sale of tyres since 1972. The company has manufacturing units in India and The Netherlands. It is also setting up a new manufacturing facility in Hungary; The Company markets its products under its two global brands - Apollo and Vredestein.

Apollo Tyres had clocked a turnover of US$ 2.08 billion, backed by a global workforce of approximately 16000 employees.

For their one of tube manufacturing facility at Pune location, we were a part of business Process Re-engineering & its expansion.

The tube manufacturing process consists of Mixing, Extrusion, Green tube building/Splicing & curing. As a part of BPR, we identified problems from their existing process & suggested relevant solutions.

Identified Problems & Suggested Solutions:-

• 10 % Cycle time has been increased in mixing area. We suggested Raw material weighing machine’s calibration at periodic basis.
• Previously cutting of green tube was taking on a separate area called as cutting area. We suggested them to have a cutter on Belt conveyer itself. Before starting the production, we ask them to set a required length at cutter level. This eliminates their additional cutting operation & saves time considerably.
• In splicing area, they used to join two ends of tube with a cutter. This process was taking considerable time. We suggested them to use heated cutter (temp of cutter at 60 degree). This saves their time in overall production.
• We introduced & implemented concepts of 5’s, Kanban, & ABC analysis. This overall helps them to reduce cycle time considerably & minimizes the scrap.
• In Curing area, they use to maintain constant Mould temperature throughout the year with specific cycle time. We suggested them to keep temperature based on seasonal temperature. This helps them in energy saving & increase in overall production.

This helps us ATL to increase in Production, cutting down the cycle time, Equipment break down time, Minimizing the scrap generation which indirectly helps in Productivity & overall profitability.