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Bottleneck identification in a tyre manufacturing plant using simulation

analysis and productivity improvement

Article  in  Materials today: proceedings · January 2018

DOI: 10.1016/j.matpr.2018.10.270

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Materials Today: Proceedings 00 (2017) 0000–0000 www.materialstoday.com/proceedings

IConAMMA_2017

Bottleneck identification in a tyre manufacturing plant using

simulation analysis and productivity improvement
Srijit Krishnana, Sarang Dev Aa, Rahul Suresha and A Sumeshb
a
B.Tech Mechanical Engineering Student, Department of Mechanical Engineering, Amrita School of Engineering,
Coimbatore, Amrita Vishwa Vidyapeetham, Amrita University, India,641112.

b
Corresponding author: Assistant Professor, Department of Mechanical Engineering, Amrita School of Engineering,
Coimbatore, Amrita Vishwa Vidyapeetham, Amrita University, India,641112.

Abstract

As the world is growing more and more competitive it is vital to improve the productivity constantly with cutting edge technologies
for any manufacturing or service industry. Quality with quantity is the main characteristic which helps a company to stay in the
competition. Technology has taken leaps of development lately and this has brought about an immeasurable increase in the
customer requirements and demand. The complete elimination of waste is the target of any qualified system with increased
productivity leading to increased profit. The tyre manufacturing company which we took for study in the need of reducing non
value added activities, bottlenecks and processing time hence increasing the productivity. This paper presents the current process
simulation of the processes undergone in a tyre manufacturing plant. It was found from the simulation that the throughput was 1170
units per day which match with actual figures produced in the plant. The simulation results shows the bottleneck present in the
plant as calendaring process. The Pareto analysis was used to validate the bottleneck simulation analysis result and matched with
it. Root cause for problems were identified using 5 why analysis and cause and effect diagram. Solutions were brought up to reduce
process times viz bottle neck were experimented, which shows increase in throughput of the tyre manufacturing plant. The
bottleneck can be eliminated by modifying the calendaring machine to increase the productivity by 15.81%. The breakeven time
for that installation which costs 3.5crores will be only 88 days. By going with an automated temperature measuring system the
productivity can be increased by totally by 18.8% from the existing scenario.

© 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of International Conference on Advances in Materials and Manufacturing Applications
[IConAMMA 2017].

Keywords: Manufacturing system simulation, Discrete Event Simulation; Cycle Time Reduction; Bottleneck Analysis; Throughput Analysis;
Pareto Analysis; Cause Effect Diagram.

2214-7853 © 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of International Conference on Advances in Materials and Manufacturing Applications
[IConAMMA 2017].
2 Srijit Krishnan, Sarang Dev A, Rahul Suresh, A Sumesh / Materials Today: Proceedings 00 (2017) 0000–0000

1. Introduction

Most of the pneumatic tyres are manufactured using a standardized process. Tyre companies start with start with
bulk raw materials such as rubber, carbon black and chemicals these are mixed according to the various tyre model
requirements [1]. The process flow takes place during the tyre manufacturing is shown in figure 1.

Fig.1. Process chart for the tyre manufacturing plant in study.

Compounding is the operation of bringing together all the ingredients required to mix a batch of rubber compound.
Each compound have a different mix of ingredients according to the properties required for particular model of tyre.
Mixing is the process of blending these ingredients which is done in the Banbury Mixer. Extrusion process is done by
the extruder in which the compound is pushed through a die, after which the extruded profile is vulcanized in a
continuous oven and cooled to terminate the vulcanization process. These material was either rolled up on a spool or
cut to length. Using this extrusion process sidewall profiles and inner liners are also manufactured. During calendaring
process, squeezing of this rubber into thin sheets and inserting a fabric normally nylon in between them to form plies
was done. In steel calendaring thin steel wires are used instead of fabric. The end product of this process are boy plies
and belts. Bias Cutting involves cutting big rolls of plies to smaller rolls depending on the requirements of the tyre and
specifications. For bead construction, beads the rings of steel wire coated with rubber are constructed. Tyre building
is the process of assembling all the components onto a tire building drum. Curing is the process of applying pressure
to the green tyre in a mould in order to give it its final shape, and applying heat energy to stimulate the chemical
reaction between the rubber and other materials. At the end of cure the pressure is bled down, the mould opened, and
the tire stripped out of the mould. The tyre may be placed on a PCI, or post-cure inflator, that will hold the tyre fully
inflated while it cools. For the final step, the final inspection is done where tyres are inspected by human eyes for
numerous visual defects such as incomplete mould fill, exposed cords, blisters, blemishes, and others. After passing
the inspection the tyres were send into the stores. So in this work using simulation the above steps involved in the tyre
manufacturing were simulated and studied. The methodology adopted in this works is explained below.

2. Methodology

The below figure 2 explains the methodology adopted in the tyre manufacturing industry for determining the
bottlenecks. Initially a general survey was conducted followed by process study of tyre manufacturing in the plant.
From the obtained data in process study, a simulation model using arena simulation package was conducted [2] and
results were analyzed. Pareto analysis the lean tool was done to verify and validate the bottle neck results obtained
from the arena simulation. Using Cause effect diagram the root causes were identified and tried to eliminate it. The
improved results after implementations were highly encouraging.
 Srijit Krishnan, Sarang Dev A, Rahul Suresh, A Sumesh/ Materials Today: Proceedings 00 (2017) 0000–0000 3

Fig.2. Methodology chart.

3. Simulation Analysis

Here we considered the 5 different popular models of tyres which this industry is manufacturing. Using arena
simulation software the process involved in the tyre manufacturing was simulated and the details were discussed
below.

3.1. Arena Model

The simulation software Arena enables the user to give specific inward and process times and attributes and also
the resources required to complete each activity [3 to 7]. To create the simulation these are the steps carried out. The
simulation model for the tyre manufacturing industry in study was shown in figures 3 to 5. In figure 3 the different
raw materials like Fabric, base and side, bead entry to the manufacturing line was shown. These entered components
were moved to the corresponding processes which is shown in the figure 4. Like the fabric after batching it’s moving
to the calendar process etc. after independent operations these components are matched and taken in to tyre building
unit which is shown in the figure 5.
4 Srijit Krishnan, Sarang Dev A, Rahul Suresh, A Sumesh / Materials Today: Proceedings 00 (2017) 0000–0000

Fig.3. Arena model- create and assign part.

Fig.4. Arena model- Entity flow based on attributes.

Fig.5. Arena Model- final part of the model

3.2. Modules in Simulation study

The data which collection was done using time study methods. Using stopwatches for multiple times entry,
processing time were recorded [8]. These timings were added into input analyzer to get the arrival and processing time
distributions. The detailed expression of each modules were illustrated below.
Part entry and assign: The part entry to the system was done using create modules. In create module the entry of
part can be expressed as schedule or based on time between arrivals. Here time between arrivals was chosen and it’s
shown in table 1. The part entry units are in minutes and whenever the first component enters into the system the
simulation clock begins to start. In this model the input entries were not restricted and at a time only one part enters
the system. Entities leaving from the create module were assigned to the specific tasks using the assign module. In
order to identify the components (entity) separately attributes are used to specify each entity within the simulation
model shown in figure 3. The table 2 indicates the corresponding data input for this model. The entity types used in
this models are ‘ply_roll’, ‘base_and_cap’ and ‘bead’.

Table 1. Create Modules in model.

Name Entity Type Type Value Expression

Create Fabric ply_roll Random (Expo) 1 154 + 0.48 * BETA(0.833, 0.85)
Create base and cap base_and_cap Constant 1.3 1
Create Bead bead Expression 1 1.19 + 0.12 * BETA(0.511, 0.739)
 Srijit Krishnan, Sarang Dev A, Rahul Suresh, A Sumesh/ Materials Today: Proceedings 00 (2017) 0000–0000 5

Table 2. Assign Modules in model.

Name Assignments
Assign calender attributes 4 rows
Assign extruder attributes 4 rows
Assign bead attributes 4 rows

Each assign module were given 4 assignments each and the entered data are shown in Table 3, Table 4 and Table 5.

Table 3. Assignments for Assign calender attributes.

Type Attribute Name Entity Type Entity Picture

Entity Picture Attribute 1 Entity 1 Picture.Yellow Ball
Entity Type type ply_roll Picture.Report
Attribute put_together Entity 1 Picture.Report
Attribute Entity.Sequence Entity 1 Picture.Report

Table 4. Assignments for Assign extruder attributes.

Type Attribute Name Entity Type Entity Picture

Attribute put_together Entity 1 Picture.Report
Entity Type type bead Picture.Report
Entity Picture Attribute 3 Entity 1 Picture.Red Ball
Attribute Entity.Sequence Entity 1 Picture.Report

Table 5. Assignments for Assign bead attributes.

Type Attribute Name Entity Type Entity Picture

Attribute put_together Entity 1 Picture.Report
Entity Type type base_and_cap Picture.Report
Entity Picture Attribute 3 Entity 1 Picture.Ball
Attribute Entity.Sequence Entity 1 Picture.Report

Station and Route modules are used to define the precedence and successor relations in the sequence of
flow of parts. In this models six stations are used namely: Enter, Station 1, Station 2, Station 3, Station 4, and Station
5 all of which are shown in figure 3, figure 4 and figure 5. Table 6 shows how sequence of movements namely S1, S2
and S3.

Table 6. Sequences in model.

Sequence Name Sequence followed

S1 Station 1 Station 5
S2 Station 2 Station 4
S3 Station 3 Station 4

The route modules consist of routes for entites based on sequence specified. Here route time or transporation time
can be added. But in this case the route time is neglected. The route modules and related data is shown in Table 7.
6 Srijit Krishnan, Sarang Dev A, Rahul Suresh, A Sumesh / Materials Today: Proceedings 00 (2017) 0000–0000

Table 7. Route module data.

Name Destination Type To

Route by entity sequence By Sequence Station 1/Station 2/Station 3 (Based on attribute)
Route 1 By Sequence Station 5
Route 2 By Sequence Station 4
Route 3 By Sequence Station 4

From the table 8, the processing time entered in the process modules used in this model is shown. The logic
used in the process module is seize delay release. The expression for the recorded time values obtained from input
analyzer was shown below.
Table 8. Process Module entry.

Expression
Delay
Name Type Tyre A Tyre B Tyre C Tyre D Tyre E
135 + 2.28 * 115 + 1.2 * 193 + 0.25 *
Fabric Expressi BETA(0.0527, BETA(0.831, 154 + 0.48 * BETA(0.0685,
Calender on 0.0823) 0.734) BETA(0.833, 0.85) 0.0432) UNIF(135, 136)
0.999 + 0.121 * 16.2 + 0.19 *
Fabric Bias Expressi BETA(0.0462, BETA(0.983,
Cutter on 0.0364) UNIF(16, 16.2) 0.884) UNIF(16, 16.2) UNIF(15, 15.4)
1.19 + 0.12 1.19 + 0.12 1.19 + 0.12 1.19 + 0.12
*BETA(0.734, *BETA(0.734, *BETA(0.734, 1.19 + 0.12 *BETA(0.734,
Extrude Constant 0.831) 0.831) 0.831) *BETA(0.734, 0.831) 0.831)
17.3 + 1.75 * 18 + 2.32 *
Tyre Expressi TRIA(16.5, 16.5, BETA(0.796, BETA(0.0161, 19.1 + 1.45 *
Building on 16.5) 0.747) UNIF(18, 19) 0.0126) BETA(0.856, 0.718)
0.999 + 0.121 * 1.09 + 0.12 * 1.19 + 0.12 *
Bead Expressi BETA(0.0462, BETA(0.739, BETA(0.511, 1.29 + 0.12 * 1.19 + 0.12 *
Construction on 0.0364) 0.511) 0.739) BETA(0.511, 0.739) BETA(0.511, 0.739)
Curing Constant 1 1 1 1 1
Expressi 134 + 3 * 94.5 + 5 *
PCI on BETA(1.35, 0.958) BETA(0.939, 0.8) UNIF(110, 115) UNIF(118, 119) TRIA(127, 128, 129)
2 + 0.441 * 2 + 0.121 *
awling Expressi 2 + 0.331 * BETA(0.0219, BETA(0.0462,
process on BETA(0.32, 0.361) UNIF(2, 2.44) 2 + EXPO(0.134) 0.0357) 0.0364)

The decide module in figure 5 allows decision making processes in the system where decision is based on
2-way by conditon.The conditon specified is that entity type is base or cap.
When an entity arrives the match module, it is placed into one of five associated queues based on entry
point to which it is connected. Entities will remain in its respective queues until a match is found. The matched entities
are then synchronized to depart from the module. The module Match 3 in figure 5 is set to match 3 entities where they
are based on the attribute put_together.
The dispose module is used as the ending point for entities in the simulation model. Entities statistics are
recorded before the entity is disposed.
The number of replications provided in this module is 10 with replication length of 24 hours. Reports were
automatically generated for every replication of the model and the summary was obtained. The detailed results
obtained during simulation study was discussed in the next chapter.

4. Results and Discussions

Basically three sorts of results will be interested from the simulation study [9]. Throughput analysis which tells us
how many raw material was converted into the useful work. The make span analysis will give the information about
the time required for producing the queue statistics will give the information about bottlenecks in the production line.
 Srijit Krishnan, Sarang Dev A, Rahul Suresh, A Sumesh/ Materials Today: Proceedings 00 (2017) 0000–0000 7

4.1. Simulation results

The below figure 6 shows the plot of collected queue statistics for the 5 different variants of tyre produced in the
plant.

Fig.6. Average waiting time in queue for each of the tyre models.

It can be inferred from the above plot that fabric calendaring process is the process with the maximum bottleneck
for all the five models of tyre produced. For the tyre C Bead construction is also a bottle neck process followed by
with awling process. Upon comparing Fabric calendaring process within the flow consumes maximum in queue and
the next machine was starving for the job make it a critical process and the corresponding as the critical machine
within the system. Addressing this issue of calendaring sometimes make the others process like Awling as critical or
on the vice versa.

4.2. Pareto Analysis

This tool is used in industries with many processes, to identify the existing bottlenecks, in the manufacturing plant.
The Pareto analysis was used in this project for all the processes that takes place inside the tyre manufacturing plant.
It is done using the process timings of extrusion, bead making, tyre building, fabric calendaring awling and PCI. All
the above process timing were taken down in detail with 5 reading each and the average timing of these readings were
taken to create the Pareto chart.
The chart was plotted using Microsoft Excel Software and each process were charted for 5 tyres which were taken
for the study with the help of this chart, we were able to establish the common bottlenecks occurring in all the 5 plots.
This analysis gave rise to our process modifications which we have established in order to reduce the bottlenecks so
as to improve the overall productivity. Figure 7 shows the results obtained from the Pareto analysis. A Cumulative
time percentages table was made for each tyre and its corresponding Pareto chart is made and shown below.
8 Srijit Krishnan, Sarang Dev A, Rahul Suresh, A Sumesh / Materials Today: Proceedings 00 (2017) 0000–0000

Fig.7. Pareto Chart for Tyre models in study

Results obtained from the Pareto Analysis of the processes shows similarity with results from the arena simulation.
The major reason for production time to increase are same as those pointed out from the arena simulation. The Pareto
analysis is used to validate the results of the simulation. Focus is given to the time consuming processes and
implementations can be made decrease production time. The Pareto chart is used as a validation tool for the results of
the simulation.

4.3. General Study

The survey conducted included members of the department was given a rating card in order to rate the department
on the basis of problem faced and productivity of that department. The rating was at a scale of 1 to 5, where 1 being
the worst and 5 being the best. The cumulative result of the general survey is taken as the basis for continuing with
that rated department and is shown in figure 8.

Fig 8. General Survey Chart.

 Srijit Krishnan, Sarang Dev A, Rahul Suresh, A Sumesh/ Materials Today: Proceedings 00 (2017) 0000–0000 9

From the general survey, calendaring have been validated as the major problematic area and the scope of
improvement is high. The focus of the project is to improve this area and increase the productivity of the plant.

4.4. Cause and Effect Diagram

Also known as the ‘Fishbone’ diagram shown in figure 9, the Cause and Effect diagram is an effective and a simple
tool for listing out the many possible causes for a problem [10]. It is used to identify causes of imperfections occurring
during the manufacturing of a product in order to determine the sources of such variations created by the defects. This
tool is employed in this project to locate the sources of bottle necks and to analyze the reasons for such occurrences.
Ishikawa diagram shows various causes for the low production. Among these, certain causes/processes were taken
under consideration for process modification so as to further enhance the productivity, the 5 why analysis was chosen
to determine the source(s) of those specific causes/process.

Fig.9. Root cause analysis diagram

The 5 WHY analysis mode of analysis was employed individually for the various causes/process which had a direct
impact in the productivity. This analysis was employed in extrusion, calendaring, green tyre making, bead construction
and curing process. The sets involved in the implementation of 5 why analysis was shown below.
1. Why reduced tyre production?
Ans: Lack of green tyres for curing
2. Why lack of green tyres?
Ans: Too much time taken for producing green tyres
3. Why green tyre production takes time?
Ans: The calendered rolls are taking too much time to get standardized after each roll.
4. Why are the rolls not being set properly?
Ans: Each roll has a specific standard temperature and it takes time for the calendar rolls to be set at that
temperature.
5. Why are rolls taking time to be set at the required temperature?
10 Srijit Krishnan, Sarang Dev A, Rahul Suresh, A Sumesh / Materials Today: Proceedings 00 (2017) 0000–0000

Ans: There is no fixed temperature reading apparatus to know whether the temperature is correct or not. It is guessed
by physically feeling the rolls temperature and checking the output rolls for cracks or mushiness (depending on under
heat or over heated cases)
The above method was applied to all other causes/processes in the fishbone diagram and which helped to identify
the source(s) for other causes. Once the root cause was established like outdated equipment in case of calendaring
machine, Inventories were accounted using manual data entry and comparisons. Various modifications were proposed
so as to improve productivity.

5. Bottleneck Elimination

Suggested method 1: Outdated equipment in case of Fabric calendaring machine.

With respect to the fishbone diagram and from the data we collected from the Arena simulations, we found that the
calendaring machines takes too much time compared to all other process. This is because the calendaring machine
employed at the tyre manufacturing plant uses a 3 roll calendaring machine.
This calendaring machine requires two passes of the same fabric for the rubber compound to be attached on both the
sides of the fabric. In the first pass, the fabric is coated with the rubber compound on one side as the fabric is pushed
through the rolls leaving the other side of the fabric blank. Once the entire roll is collected on the other side of the
machine, this roll is transported back to the beginning of the machine for the 2nd pass via a trolley or an overhead
crane. In this pass the blank side is coated with the compound. This method is very much time consuming as well as
waste of money, power and labour. For example, the fabric calendaring for the tyre model E for a roll of a kg, takes
48 minutes for 1st pass and 52min for the 2nd pass. Thus a total of about 135 minutes is taken for the whole roll as is
shown in table 9.
Process modification: It has been found that the 3 roll calendaring machine can be replaced with a 4-roll calendaring
machines which are available in the market. This replacement reduces the time by almost 40%. This is because, with
the help of the 4th feeding roll on the bottom in addition to the roll at the top, a fabric can pass through the calendar
while the rubber compound can be attached to the fabric on either side simultaneously in one pass. There by
eliminating the additional time for 2nd which results in less labour, power and time leading to lower costs and improved
productivity. The introduction of a 4 roll calendaring machine removes the need for a second pass and reduces process
time for Fabric calendaring. It can also be noted that paper by Francis Curtis [11] offers improvements in the design
of the calender roll itself which can be implemented.

Table 9. 2nd Pass Process Times.

Model 2nd pass time(minutes)

Tyre A 58
Tyre B 47
Tyre C 25
Tyre D 50
Tyre E 52

The figures 10 (a) and (b) show a general drawing of a three roll calender and a four roll calender machine respectively.
 Srijit Krishnan, Sarang Dev A, Rahul Suresh, A Sumesh/ Materials Today: Proceedings 00 (2017) 0000–0000 11

Fig.10. (a) Three roll existing-calender design; (b) Four roll proposed-calender design.

Table 9 shows process timing that can be reduced from the total process time calculated from time study by introducing
the 4 roll calendaring machine. A change in production per day is seen with this implementation and is shown in table
10.

Table 10. Number of output tyres under current and use of 4 Roll Calender.

Model Current Scenario Modified scenario

Tyre A 240 270
Tyre B 300 305
Tyre C 210 270
Tyre D 180 240
Tyre E 240 270

Suggested method 2: Calendaring machine rolls are not preheated properly for required temperature since the
preheated temperatures for these rolls are measured physically by hand using intuition and experience. Due to lack of
proper temperature readings for the rollers in the calendaring machine were not able to process it properly leading to
rejection of the part or additional time spending in the machine. Therefore these Mistakes consumes a lot of time and
also each rubber compound requires different preheating temperatures it is very difficult for a person to judge the
exact temperature by hand, the first pass of almost every compound usually generate unusable compound which cannot
be attached to the fabric for generating plies. This wasted compound varies from 20m to 50m in length. If the
temperature is above the specific temperature of the rubber compound, the compound becomes too sticky and mushy
and if the compound is under heated, it would be hard and brittle and doesn’t stick onto the fabric.
Process modification: In order to overcome this flaw, we thought of using a pyrometer to get the initial temperature
of the rolls without any physical contact. A pyrometer can be used to measure the temperature of any given surface
without any physical contact. It is done using the principle of pyrometry were the temperature of a surface is
established from the analysing the spectrum emitted from thermal radiation. A change in production per day is seen
with this implementation and is shown in table 11.

Table 11. Number of output tyres under current and use of Pyrometer.

Model Current Scenario Modified scenario

Tyre A 240 243
Tyre B 300 305
Tyre C 210 240
Tyre D 180 180
Tyre E 240 270
12 Srijit Krishnan, Sarang Dev A, Rahul Suresh, A Sumesh / Materials Today: Proceedings 00 (2017) 0000–0000

Table 12 shows the change in production seen per day on implementation of both 4 roll calendar and the pyrometer.

Table 12. Number of output tyres under current and use 4 Roll Calender and Pyrometer.

Model Current Scenario Modified scenario

Tyre A 240 270
Tyre B 300 305
Tyre C 210 298
Tyre D 180 247
Tyre E 240 270

6. Conclusion

The process involved in tyre manufacturing was studied. Based on process study using simulation model using
arena was created. Bottleneck analysis, throughput, makespan were determined from the simulation results. The
results matched that of the Pareto analysis done. Productivity was increased and modifications were proposed. The
bottleneck process was identified as the Fabric Calendering process. There will be a significant improvement in
production by implementing a 4 roll calendering machine instead of using the current 3 roll calendering machine.
Using a 4 roll calendering machine removed the need of a 2nd pass that reduced process time for the fabric calendering
process. The Table 13 shows productivity statistics achieved after implementation and the increase in production in
percentage for the tyre models.

Table 13. Throughput per day.

Percentage
Model Initial Throughput (units/day) Final Throughput (units/day) Increase

Tyre A 240 270 12.50%

Tyre B 300 305 1.7%

Tyre C 210 298 41.90%

Tyre D 180 247 37.20%

Tyre E 240 270 12.50%

Addition to this, it is noted that using a pyrometer, the initial time to get the required temperature for the given
calendar roll can be confirmed with proof rather than physically touching the rolls to determine and guess the correct
temperature. Hence the initial waste generated from under heating/overheating (approximately 20m of compound)
can be avoided entirely and the production can begin as soon as the shift starts.
Furthermore, productivity can be improved further with automation of transport systems between processes in the
plant. This drastically reduces time and increase productivity. This gives a future scope to the project.

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