I

NTRODUCTI
ONTOCEATTYRECOMPANY

CEAT TYREwasest abli

shedi n1958.I n1982,t heRPG
Groupt ookoverCEATTy r
esofI ndi
a, andin1990, renamedt he
companyCEATLt d.CEATTYREcompanyi slocatedi nHal ol
nearVadodar a,Mumbaiand Nasi k.AtHal olPl anti twas
foundedi n2009andcommer cialpr oducti
onst artinmar ch
2011.Companyi smai nl
ydeal i
ngwi thTYREofHeav yv ehi
cles
l
ike Trucks,
Buses et c.
As wel las f ort he Cars.Mainlythe
companypr oducest wot y
pesoft y r
esont echnologyRadi al
technol
ogy and Bi as technology.For each & ev er y new
i
nnov at
ions,
newt echnologycompanyi salway seffort
ingbyi ts
Research&Development Depar tment .
The pl ant in Hal ol is
spreadedin160acres.

Max imum pr oducti

oni ncompanyi scar ri
edoutbymeansof
machi nerysubdivi
dei nv ar
iousactivi
ti
eslikeinceptionofr aw
mat eri
al,mixi
ngpr ocess,makingjackets,coveri
ngt heproduct
and then conv ert
ing i
ti nt
of i
nished goods.Fi nal
lyFinished
goodsar epackedandar esealedwher eproductionbatchnoi s
embossed f or its future verif
icati
on r equir
ed.Company
defectiv
er ati
oi sl essthan1per centwhi chshow t hehow
eff
ect i
vecompanywor ks.
CEAT’ sjourneyst art
ed i n 1958,wi t
h Wor l
i,Mumbaias i ts
headquart er
s.The companyi sa subsi di
aryofRPG Gr oup.
Beingint hebusi nessf oralmostsixdecades, Ceathascreat ed
animpr essiveandr el
iableimagef orit
selfi
nt heIndi
anmar ket.
Now,wi that urnoverof95, 000plust yr
esadayi tisamaj or
pl
ay eri
nI ndianTy reIndust r
y.Oneoft heuniquefeatureofthei r
productsi stheir“compar at
ivel
ycheaper ”costthant herivals.
And,thatt oowi thoutanycompr omi seont he“quali
ty”aspect .
The company i s adamantt of oll
ow its corev alues since
i
ncept i
on.Thei rcorev aluessum upt hei
rwor k
 FACI
LITYPROVI
DEDBYCEATTYRETYRE

CEAT is notr est

ing on t
heirl
aur
els.Outhungerf or
growt
hcontinueswithanupcomingplantandpr oducti
on
ofvari
ousPCRandTBRsi zesfort
heI ndianaswel las
expor
tmar ket.CEATislooki
ngatexpandingit
scapaci t
y
f
rom 9.
4Lacst
yrespermont
hto3mi
l
li
ont
yres.
Forbett
erdel
iv
erance,t
heyarewor
kingtowardstechnical
col
labor
ati
onswithl
eadingt
yremaj
orsacrosstheglobe.

Manuf
act
uri
ngFaci
l
iti
es
CEATi
sgr
owi
ngatani
ncr
edi
blepace.

4manuf
act
uri
ngpl
ant
s-3i
nIndi
aand1i
nSr
iLanka

10out
sour
cinguni
tsf
ort
yres,
tubesandf
laps

3dedi
cat
ed2-
3-wheel
erpl
ant
scont
rol
l
edbyCEAT
 I
NFORMATI
ONREGARDEDTOEMPLOYEES
I
NCEATTYRE

 Most l
yt wo types ofEmpl oy
ees worki
ng wit
ht he
organizat
ion.
Associ
ates(
Dipl
oma/Engi
neer Fresher
s)
andM1&Abov e(
Managers).

 Provi
ding Tr
aini
ng,Know y
ourmachi
ne ,
On t
he j
ob
tr
aini
ngforfr
eshers.

 Pr
ovi
dedMedi
cal
camp

 Femal
eempl
oyment
,

 NGO,Lear
ning t
he new t
hings f
ort
he ot
herpeopl
e
besi
detheemployees.

 Dent
alI
nsur
ance

 Li
feI
nsur
ance

 Fl
exibl
eSpendi
ngAccount
s(FSAs)orHeal
thSav
ings
Accounts(
HSAs)
 ABOUTTHEPRODUCT
 Most
lyt
wot
ypesoft
echnol
ogi
esar
eused.

(
i)
Radi
alTechnol
ogy(
ii
)Bi
asTechmol
ogy

 Rawmat
eri
alusedi
npr
oduct
.

(1)
Rubber
s:Nat
ural Rubber
,But
il
e Rubber
,Sy
nthet
ic
Rubber

(
2)Mor
ethan50chemi
cal
sar
eusedi
nthepr
oduct
.

(
3)Copperwi
rei
susedf
ort
hepur
poseofgr
ip.

 Two ty
pes of Mi x
er are used to mixt
he r
aw
mat
erai
ls.
Thesear
eMasterandFinal
Mixer
.

 Forcr
eat
ionofoneTYREi
tpassesf
rom t
otal
9phase.
 EXPORT&COLLABORATI
ONOFCOMPANY

 CEAT makeshighestex
por
tfr
om I
NDI
AinTr
uck,OTR
&LCVcat
egori
es.

 Fr
om t
hecur
rentscenar
ioCEATst
oodon3r
dRanki
n

I
ndiai
nsell
i
ngTYRES.1stRankisMRFTYRESand2nd
Ranki
sAPOLLOTYRESinIndi
a.

Ithascol
l
aborati
onwi
tht
hecopmpanyofSr
il
ankawi
tht
he
sharehol
dingof51%.

 CEATpr oducesbest -i
n-class,highper f
ormancet yr
esfora
wider angeofv ehicles,includingt yr
esf or2/3Wheel ers,
Passenger Vehi cles and Ut ilit
y Vehicles,Commer cial
VehiclesandOf f-HighwayVehi cl
esandpr oducesover35
Mill
iont yresinay ear.Repl acement ,Or i
ginalEqui
pment
Manuf acturi
ng ( OEM) and I nt
ernati
onal Business
segment saccount edf or61%,26% and13% ofCEATs
revenue, r
especti
vely,inFY20.

 Current
ly,CEATs f oot pr
intspans ov er100 countri
es
acrosst hewor l
d.CEAT haspl antsi nNashi k,Mumbai,
Halol,Amber nath,Nagpurand wi t h commencementof
operati
onsi nt heChennaipl antinFebr uary2020,CEAT
has6( six)pl
ant sinIndia.CEATalsohasamanuf act
uri
ng
faci
li
tyinSr iLankat hroughitsov erseasj oi
ntvent
ures.
TheCompanyi swor kingonexpandi ngi tsmanufact
uri
ng
capacit
iesacr osspr oductcategoriesf or2-Wheel
ertyr
es
i
nNagpur ,Commer cialVehi
clesRadi altyrepl
antinHalol
andOf f
-Highwayt yresinAmber nath.
 CEAThasdedicat edstate-
of-t
he-artR&DcentresinHalol
,
Guj
aratand Frankfurt,Germany .Buil
tont hecor por
ate
pur
poseof‘ MakingMobi l
i
tySaf er&Smarter.EveryDay.
CEATiscommi t
tedt oinnovate,rebui
l
dandhel pmi l
li
ons
ofvehi
clest
ravelsafel
y .

 Earl
ierthi
sweek,thet y
remakerrepor
tedoverf
our
-fold
i
ncreaseinconsol
idat
ednetprof
itatRs182.
18cror
ef or
thesecondquar
terendedSept
ember30.

 Wemanagedoursuppl ysit
uati
onbett
erbot hf rom the
manufacturingaswel lasservi
cingpoi
ntofv iew.These
arebroadr easonswhywehav ebeenabletogiv egrowth
i
nt hetopl
ine,"hesaid.Hesaidthedemandhasr et
urnedin
theaft
ermar ketsegment ,whi
leforOEMsandex port
s,the
demandi sv erycl
oset owhereitwasbeforetheCOVI D-19
pandemic.Howev er,he said,onlyti
me wi l
lt ellifthe
demandi ssust ai
nableornot
 CHALLENGEFACEDBYCOMPANY& I
MPROVE
 Hi
ghEmpl
oyeeTur
nov
erRat
io–mor
ethan40%pery
ear
.

 Low empl oy
ee engagement and Hi
gh Empl
oyee
Absent
ism.

I
mprovedbyt
her
esul
tofhi
ghempl
oyeeenagementf
rom
44%to68%.

 QBM ( Qualit
y-Based Management )i s CEAT way of
i
mpl ement ing TQM/ Business Ex cellence. It enables
syst
emat ic oper ati
ons to achiev e business object
ives
eff
ect i
velyand ef fi
cientl
y.Itconsi sts ofa phi l
osophy,
syst
ems, t ools and t echnique f rom Tot al Quali
ty
Management ,Tot alProductiv
eMai ntenance( TPM)and
Toyot aProduct ionSy st
em (TPS) .Theend- t
o-endquali
tyis
al
so r efl
ected i n l i
ving our ‘ Purpose’. The journey
continuesev eryday .

 Fundament alprocessessuchaspol i
cymanagement ,
dail
y
management and cr oss-
functionalmanagement hav e
been f ur
ther st r
engthened t o suppor t performance
i
mpr ovementacr oss allf unctions.I n FY 20,52, 620
continuousi mpr ovementpr oj
ect s,call
ed Kaizens,have
beeni mpl
ement ed.Asapar tofLeanManagement ,val
ue
stream mappi nghasbeendone,el i
minati
ng181Muda
(wast e)and 4000pl usMur i(ov erbur
den)f r
om v ari
ous
processes.
Whatdi
dwedo.
..
Wehavevisi
tedwholepl
antoft heindust
ryandsaw how t
he
TYREi
sactul
lymadebyt hefuncti
onofeach&ev er
ymachine
l
ikeMi
xer
,Metaldet
ect
oretc.
  RAW MATERI
ALUSED
But
aRuber,Natur
alRuber,Sy
nthet
icRuber,50Ty
pesOf
Chemical
sAndSulf
erBase,
CooperWir
e,Fabr
ic.

 Car
bonnChar
gingMachi
ne:
-

InTheStar
ti
ngOfTheProcess,
But
aRuber,
NaturalRuber&
Synt
het
icRuberar
eSendedToCarbonnChargi
ngMachi ne,
WhereAl
lTheRuberMi
xesAsPerTheRequi
rement.

Theabov ement i
onedt yrecomponent suseabr oadv ari
ety
ofmat eri
alsl
ikedif
ferentrubbercompounds,di f
ferentt ypes
ofcar bon bl
ack,fill
ersli
ke cl ayand sil
ica,chemi calsor
mineralsaddedtoaccel erate/decel
eratevulcanisati
on.The
tyr
esal sohav esev er
altypesoff abri
cf orr ei
nforcement ,
severalki
ndsandsi zesofsteel.Someoft hest eelist wisted
orbraidedint
ostrongcables.cable

Nat
uralRubber
Natural Rubber i s an elastomer der ived from l atex,a
milkycolloi
d produced by some oft he pl antslike Hev ea
brasi
liensis. These plants produce l at ex when t hey ar e
woundedasaheal i
ngmechani sm.Thel atexiscollect edina
vesselandi ti
sallowedtocoagul atewhi chgi vesyout hesol i
d
rubberwhi ch can be furt
herpr ocessed i nt o sheet s.The
coagul ati
on process can be cont r
olled by chemi cal sl i
ke
Ammoni a,Formicaci d.Ammoni adecel erat esthecoagul ati
on
process wher eas For mic aci
d accel erates it.The pur i
fi
ed
natural r
ubberissameaspol yi
soprene.

The monomer of Nat ural Rubber is 2- met

hyl-
1,3-
but
adi
ene,
CH2=C(
CH3)
-CH=CH2.The requi
red pr
oper
ti
es of
rubberlikeelast
icit
y,i
smainlydependentont hecisf or
m of
C5H8r atherthanitstr
anscounterpar
t.Asthenaturalrubberi
s
formedbycoagul at
ionofl
atex,therelat
iveproport
ionsofcis
andt r
ansar efixedwhichcanresultindegradati
onofdesi r
ed
propert
ies.

Sy
nthet
icRubber
Syntheticrubbercanbemadef rom thepol ymerizati
onofa
vari
ety of monomer sincludi
ng i soprene ( 2-methyl-
1,3-
butadiene)
, 1, 3-butadiene, chl oroprene ( 2-chl
oro-1,
3
butadiene)
,and i sobut y
lene( methylpr
opene)wi thasmal l
percentageofi sopr enef orcrossli
nking.Theseandot her
monomer scanbemi xedi nvari
ousdesir abl
epropor t
ionsto
be

 Mast
erMi
xer
AfterMixi
ngOfRuber,Mi xerI
sSendedToMasterMi
xer
ForAdditi
on OfDif
ferentTy pes OfChemi
cal
s.And I
t
MixesRuber&Chemicals.

FinalMi
xer
:-Fi
nalMi
xerI
sMachi
neWher
eSul
furBasei
s
Added.

 Tr
ipl
exExt
rude
Tri
plexExtr
udei
sthepl
acewher
esheet
soft
yresar
e
pr
epared.

Calendar
:-I
n Cal
endarSheet
s ar
e coat
ed by Fabr
ic
&Cooper,
cal
l
edBeadWindi
ng.
 Fabricisusedf orPCR&Cooperi susedforTBR.Aft
er
Coating Sheets ar
e Checked Aut
omati
call
y by Met
al
Detectorf
oritsPerf
ect
ness.

NowFrom her
ethemat er
ial
goesintwoways,
thataref
or
PCR&TBR.ButtheaheadProcessi
ssameforboth.

 Cut
ti
ng
Asperr
equi
rement
,Machi
necut
stheSheet
s.

 RMS

I
nthi
s,t
her
ear
ethr
eel
evel
s,I
nFi
rstl
evel
3Or4Sheet
s(

AsPerRequi
rement)ar
eCombi
ned,
InSecondLev
el

Combi
nedSheet
sar
esendedt
oB&TSI
DEf
orshapi
ng

ofTy
reandi
nLastLev
el,
thati
sCARCASSSI
DE,

wher
eTy
reBasei
sCr
eat
ed.

 Cur
ving
I
nCur
ving,
Tyr
eBasei
skepti
nMOULDI
NGf
or55

Mi
nut
es,
wher
eTy
resar
eCur
ved.

I
nspect
ion

EachTy
rei
sinspect
eManual
l
ybywor
ker
s.

AtEachLev el1 Pi
ecePerCar
toni
stest
ed i
nR & D
Depar
tment
.

TheDefect
ivepi
ecesoft
yres&Cartonofwor k-
InPr
ogr
ess
arecut
tedandsol
douttosmall
erBusinesses.
PHOTOS OFTHEI
NDUSTRYVI
SIT CEATTYRE
Exper
iencef
rom t
heI
ndust
ri
alVi
sit
 Exposuretobetterindust
ri
alandbusi
nesspr
act
icesi
n
progressi
veeconomies.

Int
eracti
on wi
th Gui
des and ot
her per
son f
rom t
he
i
ndustryi
smoti
vat
ing.

 Know business skil

l
si n a gl
obalcontextencour
agi
ng
cult
urali
nteracti
ont olear
nbet t
ercoordinat
ionbet
ween
vari
ousDepar t
ment s.

 See&know’
isbet
termot
tot
han‘
read&l
ear
n’.

 Af
tercomplet
ingt
heindustr
ialvisi
t,wehav
eupgr
aded
ourknowl
edgeataver
ygreatl
ev el
.

Itwas a good learni

ng experience.In each & ev
ery
depar
tment,wegotnew i deasandnew t hinki
ngwhich
wasverynecessar
yforourPersonaldevel
opment .

 Wehavev i
sit
edtheenti
reprocessdepar
tment.Theyare
usi
ngnewt echnol
ogiest
hathelpsustounder
standabout
the r
ole of advanced technol
ogy i
n producti
vi
ty of
Manufact
uri
nggoods.

 Duri
ng i
ndustr
ial
.visi
t,wef
eelverymuch sat
isfi
ed by
acqui
ri
nginformati
onofvar
iousdepar
tment& knowi
ng
manynewt hi
ngs.

 The indust
ri
alv
isi
thel
ps how t
otr
ansl
atet
heor
yint
o
pract
ical
.

 Theyar estr
ict
lyf
oll
owingqual
it
y&saf et
yaspect
s.I
tis
desirabl
et or evi
ew vari
ous aspect
s & sum up the
industri
alv
isi
t
 CONCLUSI
ON
 Weconcludethatwhil
egoingthr
oughtheenti
rei
ndustri
al
visi
t,thecooper
ati
oni sfoundtobeverywellorgani
zed,
developed & mostidealindust
ryin ever
ywal k ofits
producti
on,admini
str
ati
on&managementaspects.

 Weext endourhear
tiestthankst
oCEATTYREf ormaki ng
20thSEPTEMBER 2021 adayt ocherishforsomeoft he
l
uckyst udent
swhoar ehonoredwithyourhumbl egesture
to get an opportunit
yt o vi
sit such an est eemed
organi
zation.

 We wantt ot hank t
o VI CE PRINCIPAL Mr.DERICK
MASCARENHA ,Oper ation Head Mr.RADHAKRISHNA
VAIDHYA USirforgui
dingandshar i
nginf
ormati
onabout
organi
zat
ionpr
ofil
eandmanuf act
uri
ngprocessatCEAT
TYRESPVT.LTD.HalolPlant

 Wealsowantt othankourdirect
orDr.P.G.KMurthySi
r
and facul
ty members,Prof.Paresh Pateland Prof
.
Jay
prakashLamori
aforcoordi
nati
ngtheI
ndustr
ial
vi
sit
.