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.  

Goodyear has been named one of the World’s Most Ethical Companies for 2026 by Ethisphere, marking the third consecutive year it has received this prestigious honour. This recognition reflects the company’s enduring commitment to fostering integrity throughout its global operations. Goodyear is the only tyre manufacturer and one of just eight automotive businesses to appear on this year’s list, which spans 17 countries and 40 industries.

Ethisphere determines its honourees through a rigorous, data-driven evaluation process that examines corporate governance, ethical culture, compliance programmes, environmental and societal impact and third-party management. A panel of experts analyses this information to identify organisations that demonstrate exceptional ethical leadership and best practices in business integrity.

This latest recognition reaffirms Goodyear’s ongoing dedication to principled conduct and responsible business practices worldwide.

Erin Lewis, Vice President and Chief Compliance Officer, said, “Receiving this recognition for the third consecutive year is a reflection of our associates’ strong commitment to acting with integrity. Goodyear’s inclusion on this respected list again this year underscores our longstanding commitment to ethical decision-making, responsible leadership and creating a culture where integrity guides every action.”

Nokian Tyres has launched the Nokian Tyres Snowproof 3P, a new premium winter tyre engineered for predictable and high-performance driving across a variety of Central European conditions. This new product integrates the company’s Nordic expertise into a tyre designed to perform reliably on snow, slush, wet and dry roads. It has been awarded the Premium TÜV SÜD Tyre Mark, an independent certification that verifies its outstanding quality and performance against rigorous benchmark standards, complementing the manufacturer's own extensive internal testing.

The tyre is intended for drivers of high-performance vehicles, sedans and SUVs who require dependable performance for daily commuting, mountain driving, long journeys and high-speed travel. The initial launch includes 50 products ranging from 17 to 21 inches, with the majority classified as XL for heavy loads, and the range is planned to expand to 98 SKUs covering 16 to 22 inches. Reflecting a commitment to sustainability, up to 40 percent of the tyre’s raw materials are renewable, recycled or ISCC PLUS certified. This advancement supports the company’s broader goal of increasing that proportion to 50 percent by 2030. Production takes place at the company's new facility in Oradea, Romania, recognised as the world's first full-scale tyre factory to operate with zero CO2 emissions in scopes 1 and 2, with select sizes also manufactured at the factory in Nokia, Finland.

The tyre’s performance capabilities were validated through extensive testing in both controlled and real-world environments. Winter testing was conducted at the Ivalo Test Center in Finnish Lapland to ensure high standards on snow and ice, while high-speed and wet performance evaluations took place at the Hakka Ring in Spain and the test track in Nokia, Finland. The Nokian Tyres Snowproof 3P becomes the flagship winter offering for Central and Southern European consumers, joining the Seasonproof 2 for all-season and the Powerproof 2 for summer in the company's latest product lineup.

The tyre features a Triple Zone Tread designed to enhance safety and control. This includes an Arctic Zone with 3D siping for improved snow grip, an Aqua Zone with a blade groove design to increase groove volume and resist aquaplaning and a Performance Zone with optimised geometry for enhanced directional stability and cornering precision. The Alpine Grip Compound incorporates a new generation of polymers and renewable resins, alongside the highest proportion of silica ever used by the company in a winter tyre for this market. This high silica content ensures responsiveness in cold temperatures, supports wet grip and contributes to lower rolling resistance for improved efficiency. The Power Lock Core utilises Performance Bead Rings to enhance stability and handling during sudden, high-speed manoeuvres.

Durability is addressed through the inclusion of Aramid Strong Sidewalls on all sizes 17 inches and above. These sidewalls embed lightweight aramid fibres, a material also used in defence and aerospace industries, to reinforce the tyre against impacts from potholes and road hazards and reduce the risk of punctures. A large rim protector is also incorporated to shield wheels from curb damage. The tyre is designed to seamlessly fit both internal combustion engine vehicles and electric vehicles, carrying the Electric Fit emblem to signify it has been developed and tested to meet the specific demands of EVs regarding weight, noise, torque and range. It also features SilentDrive Technology, which uses a layer of acoustic foam attached to the inner liner to dampen bothersome frequencies and provide a quieter, more comfortable cabin experience.

Tommi Alhola, Senior Vice President – Central Europe, Nokian Tyres, said, “As electric vehicles and SUVs become more popular in Europe, larger rim sizes and heavier loads are more prevalent than ever. The diverse size options and outstanding safety and performance properties of the Nokian Tyres Snowproof 3P meet the needs of Central and Southern European winter drivers as their vehicle choices evolve.”

Martin Dražík, Product Manager, Nokian Tyres, said, “We developed the Nokian Tyres Snowproof 3P to balance ultimate confidence with exciting performance. Central European consumers demand a product that keeps them safe in a wide array of winter conditions without sacrificing an enjoyable driving experience. We spent years preparing the Snowproof 3P to blend Nordic winter know-how with the unique properties needed to thrive in unpredictable winter conditions.”

Bridgestone will continue as a tyre supplier to the FIM Endurance World Championship (EWC) in 2026, extending its partnership with the series which began in 2017. The company will increase its involvement by equipping seven teams with its premium BATTLAX motorcycle tyres, a rise from the five teams supported the previous year. The seven teams are AutoRace Ube Racing Team, BMW Motorrad World Endurance Team, F.C.C. TSR Honda France, Kawasaki Webike Trickstar, KM99 Yamaha, Yamalube YART Yamaha EWC Official Team and Yoshimura SERT Motul.

This expanded role follows a highly successful 2025 season where a Bridgestone-equipped team, Yamalube YART Yamaha, claimed the EWC title. This victory marked the sixth championship win for a team using Bridgestone tyres and the fifth consecutive year of such dominance, with five of the top six overall positions occupied by Bridgestone-supported teams.

The BATTLAX racing tyres are the result of advanced engineering, utilising sophisticated materials and construction methods to provide superior grip, consistent performance and lasting durability. These qualities are essential for the demanding nature of endurance racing, which features events lasting up to a full day. Engineered to perform reliably in diverse weather and track conditions, the tyres give riders the confidence to maintain a competitive pace throughout each stint.

Bridgestone views the racetrack as a crucial development environment, using the extreme conditions of the EWC to rigorously test and refine its technology. With races ranging from 8 to 24 hours, the series places continuous, intense stress on tyres, offering a perfect setting to advance compound chemistry and construction techniques. This knowledge is then applied to consumer products under the company’s From Circuit to Street philosophy. The latest proof of this process is found in new additions to the BATTLAX family, including the track-only RACING BATTLAX V03 slick tyre and the road-legal BATTLAX RACING STREET RS12, both of which feature technology honed in the crucible of endurance competition.

Nico Thuy, Director Motorcycle, Bridgestone EMEA, said, “The FIM Endurance World Championship represents the ultimate proving ground for tyre performance, durability and innovation. The 2025 season once again demonstrated the consistency and capability of Bridgestone tyres under the toughest racing conditions. Following this success, we are proud to offer our expertise and top-performing tyres to seven teams for 2026.”

The 2026 EWC season schedule is as follows:

• 18 April: 24 Heures Motos, Le Mans, France
• 6 June: 8 Hours of Spa Motos, Circuit de Spa-Francorchamps, Belgium
• 5 July: Cuca-Cola Suzuka 8 Hours, Suzuka race track, Japan
• 19 September: the Bol d'Or, Circuit Paul Ricard, France

The Yokohama Rubber Co., Ltd. has unveiled its comprehensive motorsports activity plan for the 2026 season. The company views its participation in global motorsports as essential for advancing tyre technology and reinforcing the ADVAN and GEOLANDAR brands. Its strategy encompasses a diverse range of events, from top-tier championships to grassroots competitions worldwide.

Key championships and series

• SUPER FORMULA: Yokohama Rubber has renewed its exclusive agreement as Official Tyre Partner and control tyre supplier for Japan's premier racing series, a partnership dating back to 2016. The new contract extends through the 2030 season. For 2026, the company will supply ADVAN racing tyres featuring a high renewable and recycled raw material ratio of approximately 46%. The series will also introduce the SUPER POLE QUALIFYING Supported by YOKOHAMA TYRE, a three-stage knockout format.
• SUPER GT: Yokohama will supply ADVAN racing tyres to one car in the GT500 class and 17 cars in the GT300 class, aiming for victories and a championship title in the latter.
• Nürburgring 24-Hour Race: Yokohama will supply ADVAN racing tyres to three teams: Haupt Racing Team, KONDO RACING with Rinaldi, and BMW M Motorsport. This marks the first collaboration with BMW M Motorsport in nearly 40 years, with ADVAN tyres fitted to two BMW cars entered by Schubert Motorsport and a special fan-focused BMW entry. Tyres will also be supplied for the Nürburgring Langstrecken-Serie (NLS).
• Porsche Sprint & Endurance Challenges: For the sixth consecutive year, ADVAN racing tyres will serve as the control tyre for the Porsche Sprint Challenge North America and Porsche Sprint Challenge USA West. It will also be the control tyre for the Porsche Endurance Challenge North America for the third straight year.
• Ford Mustang Cup: Yokohama will again supply ADVAN racing tyres as the control tyre for this one-make series, which features the Ford Mustang Dark Horse R.
• American Off-Road Racing Championship (AORC): Yokohama has become a supporting sponsor of this newly launched premier desert racing series. The company will supply GEOLANDAR tyres to top teams competing in the championship, which includes renowned races like Best in the Desert and The Mint 400.

Other major events and disciplines

• Hill Climb: At the Pikes Peak International Hill Climb, Yokohama will supply ADVAN racing tyres to top drivers and continue sponsoring and providing the control tyre for the Pikes Peak GT4 Trophy by Yokohama.
• Off-Road Races: Yokohama will seek a second consecutive overall win at the Asia Cross Country Rally (AXCR) using GEOLANDAR M/T G003 tyres. In North America, the company will support the King of the Hammers (as title sponsor of the Every Man Challenge), the Championship Off-Road series (with GEOLANDAR X-AT and A/T4 tyres), and the TrophyLite Series (supplying GEOLANDAR M/T G003 as the official specification tyre for the eighth year). They will also supply tyres for the XCR Sprint Cup Series in Japan.
• Rally: In the Japanese Rally Championship (JRCA), ADVAN rally tyres will be supplied to top JN-1 class teams, including the NUTAHARA Rally Team (with an ADVAN-coloured car) and SUBARU Team ARAI. Yokohama will also support the TOYOTA GAZOO Racing Rally Challenge for a second year.
• Drift: For FORMULA DRIFT JAPAN (FDJ), Yokohama will supply ADVAN NEOVA AD09 tyres to teams in the top FDJ class and provide control tyres (ADVAN NEOVA AD09 for FDJ2, ADVAN APEX V601 for FDJ3). The company will also supply ADVAN tyres to a team competing in the D1 GRAND PRIX.
• Speed Competitions: In Japan, Yokohama will supply ADVAN A052 and A050 tyres for the All Japan Gymkhana Championship and a range of ADVAN tyres for various surfaces in the All Japan Dirt Trial Championship.

Participatory & Grassroots: Yokohama will support grassroots events globally, including supplying ADVAN dB V553 tyres as the control tyre for the new CATERHAM CUP JAPAN. The company also announced its Yokohama Motorsports Scholarship 2026 programme to support participants in Japanese rally, gymkhana and dirt trial competitions.