Background

The tire manufacturing industry heavily relies on efficient processes to ensure optimal production outputs while minimizing resource wastage. One critical aspect of tire production involves the curing process, which necessitates the use of steam in Tire Curing Presses (TCP). However, inefficiencies in steam utilization often lead to significant losses in energy and productivity.

challenges

1. Steam Loss Due to High Idling Time: Curing presses may experience prolonged idle periods, resulting in unnecessary steam wastage.

2. Lack of Real-time Monitoring: The absence of a real-time dashboard made it difficult to identify and address inefficiencies promptly.

3. Energy Wastage: Heavy losses were incurred due to inefficient energy consumption during the curing process.

4. Limited Awareness of Steam Idling Reasons: The root causes of steam idling remained unclear, impeding efforts to mitigate inefficiencies effectively.

Solution implemented

To tackle these challenges, a steam utility tracking application was developed using the Ignition platform. The application was designed with the following key features:

1. Integration with Multiple Curing Press Controllers: The application seamlessly connected with over 100 curing press controllers from various brands, ensuring comprehensive coverage across the tire curing area.

2. Complex Logic Implementation: Advanced logic algorithms were incorporated to analyze data from the curing presses, enabling the identification of inefficiencies and opportunities for optimization.

3. Alert Notification System: Real-time alerts and notifications were implemented to promptly notify the curing process team and other relevant stakeholders of any anomalies or deviations from optimal steam utilization.

results achieved

After 12 months of implementing the steam utility tracking application, the following results were observed:

1. 35% Reduction in Steam Loss: By addressing idle time and optimizing steam usage, significant reductions in steam wastage were achieved.

2. 15% Decrease in Energy Consumption: Efficiencies in steam utilization translated into tangible energy savings, contributing to a more sustainable manufacturing process.

3. 8% Increase in Curing Press Efficiency: Through data-driven insights and optimizations, the overall efficiency of curing presses improved, enhancing production outputs.

4. Faster Turnaround and Reduced Idling Time: Cross-functional teams were able to respond swiftly to alerts and notifications, minimizing downtime and maximizing productivity.

5. Real-time Alerts and Notifications: The implementation of a real-time monitoring system empowered stakeholders to proactively address inefficiencies and make informed decisions.

ROI Calculation

Data collected at the 12-month mark enabled the calculation of ROI, which amounted to $500k USD. This ROI was derived from increased throughput, improved Overall Equipment Effectiveness (OEE), and decreased energy consumption. The initial investment of $120k USD yielded substantial returns, validating the effectiveness of the steam utility tracking application.

Future Endeavors

The success of the steam utility tracking application paved the way for further investments in comprehensive energy management solutions. Building upon the achievements in steam utilization optimization, future initiatives aim to extend energy-saving measures to other utilities such as compressed air and HVAC systems, ensuring a holistic approach to sustainability and efficiency in tire manufacturing.

In conclusion, the implementation of the steam utility tracking application not only addressed existing challenges but also laid the foundation for continuous improvement and innovation in tire manufacturing processes. By leveraging technology and data analytics, the industry can strive towards greater efficiency, profitability, and environmental sustainability.

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