Group Presentation Production & Operations Management

Presenters:R.A.H.B. Ranawaka MBM/05/30Chaturanga Attanayaka MBM/05/02K.D. Hasitha LakmalMBM/05/17G.R.C.R. Gunasekara MBM/05/07S.P.B. Samarawickrama MBM/05/32W.M.M A Weerasekara MBM/05/39

Date: 16 / 12 /2017

Manufacturing Process of Solid Tyre

Camso Loadstar (Pvt) Ltd Ekala

Company Profile

• In 1984, Pierre Pringiers and Philippe Danneels found Solideal and a Belgian company has expanded their business operations by venturing into international market.

• In year 1984, the company named Loadstar, as

a joint venture with Solideal and Jinasena Group, was commenced to manufacture solid tyres in Sri Lanka. At present, Loadstar is one of the world’s largest manufacturers of solid rubber tyres.

• The company manufactures exclusively for Solideal, one of the world’s leading industrial tyre distributors, which has a 20-25% share of the industrial solid rubber tyre market and operates within a network spanning 90 countries.

• In addition to solid tyres, Loadstar manufactures pneumatic tyres, rims and rubber tracks and supplies about 90% of Solideals product requirement.

Global ManufacturingCasmo operates production facilities in 10 countries to better serve their customers.

• Casmo has more than 7,500 dedicated employees spread over 26 countries around the world, with close to 200 people working in R&D, including a dedicated “advanced technology” group. They operate 3 advanced R&D centres and have 22 manufacturing plants in 10 countries through North and South America, Europe and Asia.

Raw Material Used qty Country of Origins

Natural Rubber 1000 MT Sri Lanka

Carbon Black 500 MT China, India, Thailand

Metal 60 MT India

Textile 50 MT China, Hong Kong

Zinc Oxide 40 MT China

Sulphar 20 MT China

Additives 10 MT Singapore

Synthetic Rubber 5MT USA

Supply Chain & Raw Material Used

Global Distribution To be closer to their customers, they are present in

more than 100 countries, including 20 where they have own footprint.

Camso 2015 9

OEM’s Industrial Equipment Partners

Camso 2015 10

A tyre is a ring-shaped component that surrounds a wheel's rim to transfer a vehicle's load from the axle through the wheel to the ground and to provide traction on the surface traveled over.

From the Beginning to Now

Tyre

Mainly tires can be divided into main 02 categories

Pneumatic Tires

Solid Tires

Tires

Press On Tire

Resilient Tire

Cured On Tire

Radial Tire

Bias Tires

Industrial Tires

Passenger Vehicle Tires

Industrial Tires

Tyre

Resilient Press On Cured On

Solid TyresA tyre is a ring-shaped component that surrounds a wheel's rim to transfer a vehicle's load from the axle through the wheel to the ground and to provide traction on the surface traveled over.

2 Layer

Steel Reinforcement

Heel Layer

Tread Layer 3 Layer

Steel Reinforcement

Middle Layer

Heel Layer

Tread Layer

3 Layer High Heel

Steel Reinforcement

Middle Layer

Heel Layer

Tread Layer

Resilient Tyres

Features• Reduce the down time period due to

absolute puncture resistance.• Less maintenance cost and high durability. • Stability to control highest speeding of the

vehicles due to reduce nature of tyre heating.

• Less maintenance cost & other charges of the vehicles due to less vibrations and shocks.

• Low percentage of cost / hour.

Usage of Resilient Tyres

•Forklifts•Ground Support Equipment•Port Trailers•Industrial Trailers•Access / Warehouse Equipment•Platform Trucks•Reach Stackers•Empty Container Handlers•Other Material Handling applications

Types

Xtreme

Magnum

Ecomatic

RIB,HT,ZZRIB,Mag 2

1 Layer 2 Layer

Steel Band

Tread Layer

Steel Band

Tread Layer

Middle Layer

Press On Tyres

Features

• Reduce the down time period

due to absolute puncture

resistance.

• High Stability in better vehicle

control by the operator.

• Low rolling resistance.

• Low percentage of cost / hour.

Usage of Press On Tyres

• Forklifts

• Ground Support Equipment

• Access / Warehouse Equipment

• Platform Trucks

• Reach Stackers

• Empty Container Handlers

• Other Material Handling applications

Types

PON 775+Magnum + SM FL

SD HT + SM

SD Ecomatic ETR + ESM

2 Layer 1 Layer

WheelTread LayerWheel

Heel

Tread Layer

Cured On Tyres

Features

• Low Operating cost due to non

mounting process required

• Less maintenance cost and high durability.

• Stability to control highest speeding of the vehicles due to reduce nature of tyre heating.

• Less maintenance cost & other charges of the vehicles due to less vibrations and shocks.

Usage of Press On Tyres• Scissor Lifts • Articulating Booms • Telescopic Booms • Light weight self propelled Booms • Vertical Masts • Push arounds • Trailer Mounted Booms • Other Arial Work Platforms

• Compounding and Banbury mixing

• Milling

• Extruding and Calendering

• Component Assembly and Building

• Curing and Vulcanizing

• Inspection and Finishing

Basic Tyre Manufacturing Process

Inner Heel Building

Heel Rolling Bonding

Soft RollingMolding Tread Rolling

Curing

Finishing

Manufacturing Process of Resilient Tyres

Camso 2015 29

Process Flow Chart - Resilient Tyre Manufacturing Process

245 s245 s

275 s275 s

130 s130 s

127 s127 s 200 s200 s

207 s207 s

115 s115 s

195 s195 s 95 s95 s

120 s120 s

160 s160 s

85 s85 s

Traceability flow chart

Traceability flow chart

Inner Heel Building

• Roll I.H. Compound on Collapsible core

• Insert Bead • Expand Collapsible Core• Tree types of beads are used

1. Cable Beads

2. Bead Grommet

3. Steel Rods•Spaces between Beads should be equal.•No of compound rolling should be according to the specification

Heel Rolling & Bonding

Inner heel is transferred to a expandable core

To obtain good bonding Between Heel and Middle(Soft)

An overlap should be applied

• Trapped air should be removed using a wrinkle

Bonding layer

Overlap

Soft Rolling & Tread Rolling

•Only for 3L tiresCharacteristics of Soft Compound•Ability to absorb pressure•Ability to rebound

Characteristics of Tread Compound•Withstand tearing•Withstand cracking•Endure high temperature•Survive in rough climatic conditions•Resist oils, grease etc.

Molding & Curing

•Cured tire should be de-molded on correct time

•Green tire should be centered on mold•bumping should be applied•Clamps should be tied properly

Tyre trimming and Final inspection• After the tyre de-moulding skilled operators trim extra

flash of the tyre and identify visual defects and if tyre is ok send FQC and if not ok send to the re work area.

• Inspection is to be done as some irregularities are generated on and around the tyre after the curing process.

• It is done manually by some skilled workers.• It includes 3 types of inspection

1. Visual

2. Hardness

3. Ultra Sonic (US)

• After the inspection details enter the SAP system for the traceability.

Future Requirements

• Constant improvements in rubber chemistry and tire design are creating exciting new tires that offer greater mileage and improved performance in extreme weather conditions. Manufacturers now offer tires estimated to last up to 80,000 miles.

• Treads, designed and tested by computer, now feature unique asymmetrical bands for improved traction and safety on wet or snowy roads.

• Tire design engineers are also experimenting with non-pneumatic tires that can never go flat because they don't contain air under pressure. One such non-pneumatic tire is simply one slab of thick plastic attached to the wheel rim. The plastic curves out from the rim to a point where a rubber tread is secured to the plastic for contact with the road. Such a tire offers lower rolling resistance for greater fuel economy and superior handling because of a greater area of contact between tread and road.

Productivity Performance

•Extremely shorter Mixing & Curing cycles that will lead to lowest Over Head.

•Faster Filler incorporation•(Functionalized Polymer/Filler)

•Faster Curing•(Thermal Conductivity)

•No failures even undersevere/continuous applications.- Thermal explosions- Chunking/Chipping•Low HBU•Longer Life•Good Thermal•Properties(Hot Tear Resistance )