Industry visit to CEAT Ltd

Industry visit to CEAT Ltd

1. 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)

2. 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

3. 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."

4. 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

5. Production Capacity Nashik plant established on 15 th 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

6. Values C=>Challenger A=>Aspiration led I=>Integrity R=>Result Obsession O=>Openness Appraisal system PRIDE

7. The Market Domestic Customers: Competitors (India and a broad)

8. The Tyre Manufacturing Process

9. Components of a tyre : The tyre is an assembly of numerous components that are built up on a drum and then cured in a press under heat and pressure. The Tyre Manufacturing Process

10. 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

11. 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

12. The tyre manufacturing process is done in following five stages: 1.Compounding and Banbury mixing: A b anbury 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

13. 2 . Component Part Constructing – Calendering The Tyre Manufacturing Process

14. 2.Component Part Constructing – Steel Calendering The Tyre Manufacturing Process

15. 2.Component Part Constructing - E xtrusion The Tyre Manufacturing Process

16. 2.Component Part Constructing - Bead Production The Tyre Manufacturing Process

17. 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

18. 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

19. 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