Ceat, the pioneering tyre company under Mumbai’s RPG Group, is fast-tracking the implementation of Industry 4.0 technologies across its six Indian tyre manufacturing plants. As it maintains a stronghold with a 40% market share in India’s electric two-wheeler tyre segment, Ceat is primed to secure the World Economic Forum’s (WEF) Lighthouse Certification for its Chennai facility, following the accolade awarded to its flagship Halol plant.
Enabling Industry 4.0 Excellence
With a focus on avant-garde automotive technologies, such as autonomous driving, e-mobility, and connectivity, Ceat’s pursuit of WEF’s Lighthouse Certification underlines its dedication to implementing advanced manufacturing technologies, digitization, and artificial intelligence into its production processes.
Lighthouse Certification
In January 2023, Ceat made history as the sole tyre manufacturer globally to earn WEF’s Lighthouse Certification. The certification acknowledges its groundbreaking integration of cutting-edge manufacturing technologies at its Halol plant, setting exemplary standards in areas including data and technology platforms, capability development, use-case deployment, and change management.
Global Growth Catalyst
Ceat’s aspiration to repeat its success in Halol at its Chennai plant aligns with its strategic vision. The Lighthouse Certification will seamlessly integrate Ceat into the Global Lighthouse Network (GLN), fostering best practice exchange with fellow members and strengthening its global presence among vehicle OEMs in both domestic and international markets.
Unlocking Industry Best Practices
Jayasankar Kuruppal, Senior Vice-President of Manufacturing at Ceat, emphasizes the invaluable networking opportunity presented by GLN. The network not only enhances Ceat’s reputation as an agile and progressive entity but also enriches its associations with global OEMs across diverse markets.
Digital Transformation Journey
While Ceat embarked on its smart factory journey in 2012, the comprehensive transformation commenced in 2021, serving as the cornerstone for its Lighthouse Certification achievement. Through extensive digital initiatives and a mega transformation focused on operational efficiency, Ceat solidified its commitment to digital innovation.
Impactful Benefits
Advanced Industry 4.0 solutions facilitated remarkable enhancements at Ceat. Cycle times for critical tyre manufacturing processes improved by around 20%, process scrap was slashed by 45-50%, and energy consumption reduced by 15-18%. These advancements bolstered both domestic and export businesses, effectively elevating Ceat’s industry standing.
Integral Use Cases
Ceat’s adoption of digital analytics, AI, machine learning, IoT-based sensors, and virtual reality catalyzed holistic transformation. The deployment of these technologies spanned diverse aspects of manufacturing, contributing to real-time decision-making, operator training, and troubleshooting.
Cross-Deploying Success
Ceat’s digitalization triumph at Halol is being extended to its Chennai, Nagpur, and Ambernath facilities. The company’s unwavering commitment to technology-driven advancement is propelling its presence across various locations and enhancing customer experiences.
Focused Roadmap
With a three-year digitization plan firmly in place, Ceat’s investment in digitization is projected to persist, backed by the tangible benefits and advancements achieved through Industry 4.0. As Ceat embraces technology, it solidifies its position as a pioneering force in the global tyre industry.