Industry visit report on CEAT Ltd.

Submitted By:Ketan Mokal (82)

Mridu Sharma (83)Namish Sharma (84)Namrata Kumar (85)Nikhil Nagdeote (86)

Ninad Gajbe (87)Niraj Sawarkar (88)

Background

• CEAT international was established in 1924 at Turino in

Italy and manufactured cables for telephones &

railways.

• In 1958, CEAT came to India, and CEAT Tyres of India

Ltd was established in collaboration with the TATA

Group.

• In 1982,the RPG Group took over CEAT Tyres of India.

• In 1990,renamed company CEAT Ltd.

• Head office in Dr Annie Besant Road, Worli, Mumbai

Vision and Mission

Vision:

• To be amongst the most profitable tyre companies

in India by 2016

• Leadership in 5 countries Outside India

• Market Leadership in select categories in India

• Mission:

"To nurture an exciting and challenging work

environment with fairness and transparency."

Current Scenario

• Manufactures over 6 million tyres every year.

• More than 3500 Cr annual turnover

• Operates from Mumbai ,Nasik & Halol plants.

• Export to 130 countries

• Segment wise revenue break-up Replacement market 55-60 %

OEM 20-25 %

• Tyre range : 2 Wheelers, Car/SUV, LCV/Trucks, OTR,

Farm vehicles

Production Capacity

• Nashik plant established on 15th Aug, 1973

• Current employees - 1530

Product wise production rate (in Tonnage) at Nasik Plant

• Truck – 112

• RT(Radial Tyres) – 25

• Non Truck- bias – 88

• PC & LT Radial – 18

So, Total daily (Cured Tonnage) = 243 T

Values

• C=>Challenger

• A=>Aspiration led

• I=>Integrity

• R=>Result Obsession

• O=>Openness

• Appraisal system PRIDE

The Market• Domestic Customers:

• Competitors (India and abroad)

The Tyre Manufacturing Process

• Components of a tyre :

The tyre is an assembly ofnumerous componentsthat are built up on adrum and then cured in apress under heat andpressure.

The Tyre Manufacturing Process

Typical components used in tyre assembly are listed below:

• Inner line : The inner liner is an extruded halobutyl rubber sheet compounded

with additives that result in low air permeability.

• Body ply : The body ply is a calendered sheet consisting of one layer of rubber,

one layer of reinforcing fabric, and a second layer of rubber.

• Side wall : Sidewalls are non-reinforced extruded profiles with additives to give

the sides of the tyre good abrasion resistance and environmental resistance.

• Beads : Beads are bands of high tensile-strength steel wire encased in a rubber

compound. Bead wire is coated with special alloys of bronze or brass.

• Apex : The apex is a triangular extruded profile that mates against the bead.

• Belt Package : Belts are calendered sheets consisting of a layer of rubber, a

layer of closely spaced steel cords, and a second layer of rubber. The steel

cords are oriented radially in radial tyre construction, and at opposing angles

in bias tyre construction.

• Tread : The tread is a thick extruded profile that surrounds the tyre carcass.

• Cushion gum : Many higher-performing tyres include an extruded component

between the belt package and the tread to isolate the tread from

mechanical wear from the steel belts.

The Tyre Manufacturing Process

• Chemical formulation of a tyre:

Chemical % formulation

Rubber (Natural and synthetic) 38%

Fillers (Carbon black, silica, carbon chalk) 30%

Reinforcing materials (steel, rayon, nylon) 16%

Plasticizers (oils and resins) 10%

Chemicals for vulcanisation (sulphur, zinc oxide, various chemicals)

4%

Chemicals as antioxidants to counter ozone effects and material fatigue

1%

Miscellaneous 1%

The Tyre Manufacturing Process

The tyre manufacturing process is done in following five stages:

1.Compounding and Banbury mixing:

A banbury mixer combines rubber stock, carbon black and other

chemical ingredients to create a homogeneous rubber material. Time,

heat and raw materials are factors utilized to engineer material

composition.

The Tyre Manufacturing Process

2. Component Part Constructing – Calendering

The Tyre Manufacturing Process

2.Component Part Constructing – Steel Calendering

The Tyre Manufacturing Process

2.Component Part Constructing - Extrusion

The Tyre Manufacturing Process

2.Component Part Constructing - Bead Production

The Tyre Manufacturing Process

3.Assembly of components

The components are

assembled on an automated

machine in the following

order:

Carcass Building, Inner Liner,

Body Ply: Mounting, Bead Wire

Mounting and Turn-Up,

Sidewall Mounting and

Joining, Tread package, Cap

Ply: Mounting and Joining,

Tread Mounting, First and

Second Stage Coupling and

finally Green Tyre

The Tyre Manufacturing Process

4.Curing and Vulcanizing:

The curing press utilizes heat and pressure to convert the assembly into

final tyre.

This increases rubber compound strength. In this process all tyre

components are welded onto each other and tread pattern and sidewall

graphics are engraved on the tyre.

The Tyre Manufacturing Process

5.Finishing Inspection:

Following curing, finishing operations and inspection remain to be

performed before the tyre is stored or shipped. After building the green

tyre it is transferred to the painting machine, where anti-blemish chemicals

are applied.

The Tyre Manufacturing Process