Manufacturing Revolution: Transforming Operations in the Tyre Industry

Staying ahead of the curve across various industries requires embracing cutting-edge digital technologies. In the manufacturing industry, such technologies could translate into Cloud-based manufacturing systems, which the industry has been hesitant to adopt.

However, at Apollo Tyres, we have always believed in pushing the boundaries to enhance our operations, with technology and innovation as one of our core growth pillars. Thus, our collaboration with Output Industries in creating the Cloud-based Apollo Manufacturing Execution System (MES) represents a significant leap forward in setting industry benchmarks. As a result of the successful integration of the Apollo MES, it has been a year since our Limda plant in India has been running entirely through the Cloud. Encouraged by this success, we are set to implement similar systems in four other Apollo Tyres plants, including our facility in Enschede, this August.

The Power of Cloud-Based Manufacturing

Traditional on-premises systems have long been the norm in manufacturing. However, they come with limitations regarding scalability, flexibility, and the integration of advanced technologies. By moving to the Cloud, we have unlocked various benefits that were previously out of reach, especially for a process as complex as tyre manufacturing.

One of the most significant advantages of running our MES through the cloud is the ability to integrate AI seamlessly. AI can analyse our plants, machines, and equipment accurately and in real time, allowing us to gain valuable insights into our manufacturing processes. This results in an improved ability for us to efficiently share data from one plant to another, increasing coordination between plants and promoting consistent standardisation.

Gathering such data throughout the manufacturing process also results in higher visibility of the end-to-end operation, allowing us to better predict and identify any faults and inefficiencies, such as making more informed decisions to guide material movement. There is also a drastic reduction in faults and errors in our production processes that can pose a significant and costly risk of a temporary shutdown of our plant.

Greater agility and scalability are other key benefits that we have observed. In an industry where demand can fluctuate rapidly, the ability to scale operations up or down quickly is invaluable. The Cloud-based system allows us to respond to these changes swiftly and efficiently. It is essential in tyre manufacturing because one of the core components of tyres, rubber, does not necessarily have the longest shelf life. It also means that less waste is produced, improving sustainability.

From the software and data perspective of sustainability, working together with Cloud providers means that we can leverage their large-scale computing power. These providers can run data centres more efficiently by moving operations to environmentally friendly locations, such as Iceland, which uses geothermal power for cooling. This efficiency is only provided through Cloud systems that allow data to be managed consistently in optimal locations.

Mitigating Risks

Some might say that running an entire manufacturing plant through the Cloud increases cybersecurity risks, which can be attributed to one of the main reasons other manufacturing firms have yet to adopt these new systems. Yet, our experience shows otherwise. The Cloud eliminates thousands of access points and reduces them to a single point of entry—and it is much easier to secure, manage, and monitor one than many. What is of utmost importance is equally investing in Cloud security.

Adopting Cloud Technologies

We advise other manufacturers who want to adopt similar systems to invest in training their people to bridge the digital skills gap, which is a concern for many across industries. By focusing on upskilling your team, you can make this transition smoother and more effective. The Cloud is unpreventable as it will continuously become more integral to manufacturing across various sectors, and businesses will need to adopt aspects of it to ensure higher levels of efficiency and innovation.

In conclusion, we believe that the transition to Cloud-based manufacturing systems is not merely a technological upgrade but a strategic imperative for manufacturers aiming to stay competitive. Our commitment to leveraging the latest digital technologies has proven transformative, enhancing operational efficiency, scalability, and sustainability across our plants—the successful implementation of the Cloud-based Apollo Manufacturing Execution System at our Limda plant is a prime example.