Like many other sectors, India’s tyre industry is undergoing a massive digital transformation. Companies like CEAT have been at the forefront of this shift, adopting state-of-the-art technology.

The company was recently included in the World Economic Forum’s Global Lighthouse Network due to its impactful digital transformation using Fourth Industrial Revolution (4IR) technology.

The leading tyre manufacturer has also planned to extend its technological advancements to its Nagpur plant. “CEAT’s vision for a smart factory dates back to 2015, when it commissioned its Nagpur plant. The groundwork, however, was laid earlier at Halol, where barcode tagging was introduced for traceability and error-proofing. While Nagpur became the first facility to implement a manufacturing execution system (MES), deeper analytics and machine learning capabilities were not yet in focus between 2015 and 2020,” revealed Jayasankar Kuruppal, Sr Vice President –Manufacturing, during an exclusive interview with Tyre Trends.

As Halol expanded and exports to Europe surged by the early 2020s, CEAT had to rethink its manufacturing strategy, shifting from a high-volume, low-variant model to a high-variant, low-volume approach. Once limited to 60-70 stock-keeping units (SKUs), the company's passenger car segment expanded nearly fivefold to meet European demand, requiring a complete overhaul of production workflows. 

At the same time, the adoption of silica-based compounds, which is critical for wet grip and rolling resistance, posed new challenges. These materials inherently increased cycle times, impacting capacity utilisation. While Halol was not initially designed for high-silica production, the company’s Chennai plant incorporated necessary corrections. However, tighter OEM specifications and European market requirements led to higher scrap and yield losses. 

Recognising the limitations of conventional manufacturing, CEAT turned to 4IR technology to optimise its processes. The 4IR technology refers to the advanced digital and automation-driven technologies transforming industries today. It builds on the Third Industrial Revolution by integrating AI, IoT, big data and robotics to enhance efficiency and decision-making.

“The digital transformation began at the Halol plant, expanded to Chennai and is now planned for Nagpur. Between 2020 and 2022, CEAT developed and deployed over 80 digital use cases, earning its first Lighthouse Factory designation. This data-driven manufacturing approach is now being systematically rolled out across its entire production network,” added Kuruppal.

Intelligent factories

4IR plays a crucial role in tyre manufacturing and recycling by enhancing predictive maintenance through IoT sensors, increasing energy efficiency via AI, production optimisations and advancing smart tyres with real-time monitoring.

On the other hand, an intelligent or smart factory in tyre manufacturing is defined by two core pillars, namely automation and digital intelligence. Traditionally, the tyre industry has been labour-intensive, but the shift towards smart factories is transforming operations through seamless machine-to-machine communication, real-time data sharing and AI-driven decision-making. 

The first layer of an intelligent factory is pure automation. This includes automated machines for tyre handling, programmable logic controllers for managing machine operations and automated warehousing systems to ensure smooth flow.

“For a plant to be truly smart, data must move seamlessly across all these systems, creating a connected ecosystem. This integration extends to ERP systems and advanced AI/ML-powered analytics, optimising throughput and efficiency,” said Kuruppal.   

The next stage is where operations run end-to-end with minimal human intervention. CEAT has already implemented elements of this, particularly through curing-to-dispatch automation, where tyres move untouched from uniformity testing to segregation, grading, storage, retrieval and final dispatch. It also has AI-driven IoT integrations that enhance energy efficiency, yield optimisation and first-time-right accuracy across all processes.

“The fusion of AI, IoT and automation is enabling tyre manufacturers to move from traditional manual-heavy processes to a digitally orchestrated, high-efficiency production model,” quipped Kuruppal.

CEAT’s production capacity spans multiple plants, each specialising in different tyre categories. The Chennai and Halol plants both produce 20,000 passenger car tyres daily. The Nagpur plant, India’s largest two-wheeler tyre manufacturing facility under one roof, with a capacity of close to 78,000 two-wheeler tyres daily.

Digital implementation

Curing operations in CEAT’s passenger car and truck tyre segments are almost entirely automated. While the curing medium remains unchanged, continuing with a combination of steam and nitrogen across Halol, Chennai and other facilities, the company is also exploring radical new processes, though still in the proof-of-concept stage. 

One key digital use case implemented in Chennai focused on reducing steam consumption through real-time process monitoring. Traditionally, mould heating followed fixed time cycles (e.g. 120 or 150 minutes). CEAT optimised heating based on actual temperature data, cutting steam consumption by almost 30 percent by integrating sensors and applying a machine-learning model.

The manufacturer has invested approximately INR 450-500 million in capital expenditure across its three factories to implement automation and digital transformation initiatives. On the operational expenditure side, CEAT spends INR 60-70 million annually on software licenses, infrastructure upgrades, sensors and scanners to sustain these smart factory systems.

Adopting smart manufacturing technologies has led to significant cost reductions for CEAT. Factory conversion costs at Chennai and Halol have decreased by 20-30 percent, driven by lower energy consumption, improved yield, higher manpower productivity and throughput enhancements.

Lead times from order placement to tyre dispatch have been cut by 50-55 percent, significantly improving supply chain efficiency. Additionally, material wastage has been reduced with process scrap, both component-level and finished product waste, dropping by 25-30 percent, resulting in substantial raw material savings.

Alluding to how difficult was it to implement such extensive digital changes, the executive explained, “From an infrastructure standpoint, Chennai had a clear advantage over Halol since the latter was commissioned in 2010 and 2015, when network and digital infrastructure were not as advanced. Unlike Chennai, Halol still does not have a fully integrated MES, making digital transformation more complex.”

“However, the approach to smart manufacturing differed at both plants. At Halol, the primary focus was on efficiency improvements. In contrast, Chennai underwent a more comprehensive transformation, covering the entire manufacturing chain from design and production to dispatch and supply chain optimisation. The goal at Chennai was to reduce overall turnaround time, significantly cutting the cycle from customer order receipt to final dispatch,” he added.

While Chennai benefited from a stronger digital foundation, CEAT did not merely replicate Halol’s use cases but developed new ones tailored to Chennai’s specific needs, further driving end-to-end operational efficiency.

Commenting on the challenges surrounding this paradigm shift, the executive noted, “Integrating legacy systems with Industry 4.0 technologies posed a significant challenge as ensuring compatibility between older manufacturing infrastructure and new automation, IoT and AI-driven solutions required meticulous planning and phased implementation.”

“Another critical hurdle was maintaining data quality and governance, necessitating robust validation processes, data lineage tracking and an accountability framework to enhance data integrity and reliability,” he added.

Answering whether such transformation is possible on OTR production lines, he said, “Unlike passenger or two-wheeler tyres, OTR tyres have a longer cycle time and high levels of customisation, making digital automation less complex but highly specific. While digital transformation is feasible, CEAT plans to prioritise full automation at Nagpur in the next 18–24 months, before shifting focus to digitalisation in OTR production.”

Workforce re-alignment

CEAT is reshaping its workforce strategy to align with its digital transformation, ensuring that shop floor employees are equipped and actively involved in adopting new technologies. 

It has digitised over 100 operator touchpoints to secure operator buy-in. The programme simplifies shop floor tasks through digital tools, MES integration and real-time dashboards, allowing operators to make decisions independently and reducing reliance on supervisors. Every operator has undergone basic digital awareness training to facilitate this transition. 

A key move was the introduction of business translators, who are frontline supervisors with strong technical acumen. They bridge shop floor pain points with digital solutions. Working alongside data engineers and scientists, these individuals co-develop AI-driven use cases, such as reducing setup time in mixing processes to improve efficiency. 

The company also strengthened its talent pipeline, hiring computer science graduates, a rarity in the tyre sector just a few years ago.  It has pioneered hiring female operators in the tyre industry, beginning in Halol in 2009.

“Today, 24–30 percent of shop floor employees in Chennai and Nagpur are women. While digitalisation isn’t the primary driver of this shift, automation has made traditionally labour-intensive jobs more accessible. The company also enforces pro-women policies, including home pick-ups and drop-offs, designated rest areas, female security and an internal support forum (V Power) to address workplace concerns,” informed Kuruppal.   

When asked whether digitisation will lead to a cut in vacancies, Kuruppal stated, “Contrary to fears that digitalisation reduces shop floor jobs, we find ourselves grappling with the bigger challenge of talent attraction. Post-pandemic, fewer young workers are willing to pursue manufacturing roles, with many opting for finance, retail and IT-driven careers instead. This trend is evident across major tyre-producing states like Tamil Nadu, Maharashtra and Gujarat.” 

“While automation and AI reduce physical strain and deskill certain operations, a fully manless tyre plant remains economically impractical in the near term. However, with rising labour costs and shrinking workforce interest, a fully automated future – perhaps within 15–20 years – isn’t off the table,” he added.

Sustainability through digitisation

CEAT is driving sustainability through digital transformation, reducing energy and water consumption while lowering its carbon footprint. Energy efficiency measures have led to a 15 percent reduction in power consumption at Halol and 25 percent at Chennai.

Renewable energy accounts for 40 percent of the company’s power mix, cutting Scope 1 and Scope 2 carbon emissions by nearly 30 percent. Water usage has been reduced by 30-35 percent over the past three years through steam optimisation, with future plans to eliminate steam in curing.

In green material adoption, integrating silica-based compounds in tyre manufacturing has required process adjustments as it increases cycle time. CEAT collaborates with equipment manufacturers to enhance efficiency. It has upgraded mixers to improve silica processing and support its shift towards sustainable materials.

Commenting on future plans to implement digital solutions, Kuruppal said, “We plan to integrate virtual and mixed reality into the manufacturing processes to enhance equipment maintenance and reduce mean time to service. We are also exploring AI-driven process optimisation, as these models will auto-correct processes in real-time, enhancing product consistency and accelerating decision-making. These technologies will also help identify and eliminate bottlenecks in manufacturing and planning, ensuring a more agile and efficient production flow.”

“The company is looking into GenAI to address complex operational challenges. AI-driven predictive maintenance will improve equipment reliability by forecasting potential failures before they occur. Additionally, GenAI will optimise supply chain and production planning, ensuring better resource allocation and efficiency,” he added.  

Premium tyre maker Hankook has announced its collaboration with the eagerly awaited 2025 Convoy Truck Shows. Convoy Cymru will take place on 17–18 May, Convoy Truxton on 5–6 July and Convoy in the Park on August 9–10, running alongside the British Truck Racing Championships (BTRC).

The SmartFlex AH51 (steering axle) and SmartFlex DH51 (driving axle) for long and regional haul use, which are known for their outstanding grip and mileage performance from the first to the last millimetre of wear; the SmartFlex TH31, the newest generation trailer tyre; and Hankook's newest van tyre, the Vantra Transit, will all be on display at all shows. The company will be showcasing three tyres from its Laufenn brand in addition to the Hankook line: the LF21 all-position tyre, the LF95 trailer tyre and the LZ22 all-weather drive tire. The iON evo SUV EV summer tyre and the Dynapro HP2 all-season SUV tyre will also be on show. Along with its related events, the Devon Truck Show, Truck Show Cornwall and Best of the Best, the Convoy Truck Shows will raise money for charities and local community organizations. It will also include an amazing variety of trucks, live music, entertaining fair activities and must-see stunt acts.

Event Director Mike Quartley said, "On behalf of Convoy Truck Events and the Devon Truck Show, I'm thrilled to welcome Hankook Tyre UK as sponsors for 2025 across all three Convoy events at Pembrey, Thruxton and Donington Park. Hankook has been a valued partner at the Devon Truck Show for many years, so extending our collaboration across our Convoy-partnered events was an easy decision. We truly appreciate their continued support and are confident they'll see great value in being part of these exciting shows."

Continental is running a promotional offer from 1 May to 31 May 2025 in which customers who purchase four Continental ExtremeContact Sport02 tyres will receive a USD 110 Continental Tire Prepaid Mastercard. Additionally, customers who pay for the four ExtremeContact Sport02 tyres using their Continental Tire Credit Card will earn an extra USD 90 Prepaid Mastercard, for a total refund of USD 200.

The ExtremeContact Sport02 is a ultra-high-performance tyre designed for passenger cars. With its SportPlus Technology, which offers quick handling, improved traction on wet roads and a prolonged tread life, this tyre is perfect for both the street and the racetrack. There are 77 sizes of the tyre available, with rim diameters ranging from 15 to 21 inches. The industry-leading coverage offered by Continental Tire's Total Confidence Plan supports the ExtremeContact Sport02.

This is a complete package that includes road hazard coverage, emergency travel interruption coverage, a customer satisfaction trial, a limited warranty, flat tyre roadside assistance and a mileage warranty (if applicable). During a road trip, Continental will assist with qualified expenditures in the event of a mechanical breakdown (maximum benefit of USD 200.00 per day, with a maximum benefit of USD 500.00 per year). In order to qualify for the deal, tyres need to be bought all at once. Only valid between 1 May 2025 and 31 May 2025, or while supplies last, with a qualifying purchase made in the 50 United States, Washington, D.C. and Puerto Rico.

Leading tyre manufacturer JK Tyre & Industries Ltd launched its ‘JK Tyre Steel Wheels’ in Farrukhnagar, Haryana, as part of its targeted expansion into rural India, focusing on places with a population of 100,000 or less.

The centre displays the whole line of JK Tyre products across all segments and is intended to serve as a one-stop shop for all tyre-related requirements. Best-in-market prices, industry-leading warranties and value-added services like wheel balance and tyre replacement are all available to customers. Notably, the business also provides non-truck tyres with a fast claim service. This retail growth is in line with JK Tyre's strategy goal of enhancing its last-mile presence and meeting the rapidly increasing demand in India's rural and semi-urban areas.

Over the following three months, the rural expansion initiative will be implemented in Telangana, Tamil Nadu, Maharashtra, Uttar Pradesh, Bihar and Haryana. Later this year, the programme will be expanded with a national rollout. Through strategic partnerships, JK Tyre is enabling local businesses to oversee and expand these centres in their areas as part of the rollout. These partnerships provide prospective entrepreneurs a chance to connect with JK Tyre's wide nationwide distribution network, encouraging independence, generating jobs locally and stimulating economic progress at the local level.

Anshuman Singhania, Managing Director, JK Tyre & Industries Ltd., said, "Our Rural expansion programme will help us to reach the interiors of the real Bharat that are economically vibrant but often under-served. We are not just building retail points; we are also enabling entrepreneurship and access. These centres will offer our full range of tyres and will act as vital touchpoints for our brand, delivering consistency, convenience and confidence to a fast-rising consumer base across India’s heartland.”

German tyre major Continental will shut down its tyre manufacturing plant in Alor Setar, Malaysia, by the end of 2025, affecting 950 workers.

The facility, which produces passenger cars, light truck tyres for the Asia Pacific market, and motorcycle tyres, has been operational since December 1979 and became a fully owned Continental subsidiary in May 2012.

Continental said the closure followed a comprehensive business review to safeguard its competitiveness in the Asia Pacific region. The company plans to optimise its product portfolio and manufacturing footprint in response to changing customer demand.

Despite the closure, the German tyre maker emphasised that Malaysia remains a key market in its Asia Pacific operations.

Continental will support affected employees, including career counselling, and help them find potential employment opportunities both within and outside the company, according to the statement.

The 133,000-square-metre manufacturing site is one of six Continental tyre plants in the Asia Pacific region. The company will continue to operate facilities in Hefei, China; Rayong, Thailand; Modipuram, India; Kalutara, Sri Lanka; and Petaling Jaya, Malaysia.