An Application of Quality Tools To Improve The Tyr
An Application of Quality Tools To Improve The Tyr
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Department of Mechanical Engineering, G H Raisoni College of Engineering Nagpur, India.
Abstract. The tyre remanufacturing industries are facing quality and performance issues of the
remanufactured tyres as they have developed their own tyre retreading methods due to the lack
of standardized retreading process guidelines. This study focuses on identifying the challenges
of the tyre remanufacturing process, highlighting various defects in retread tyres and their causes
so that the challenges could be mitigated and the quality and performance of the tyres could be
improved. To achieve the objectives of the study, the quality tools including fishbone diagram
and Pareto chart has been used. For the above analysis, the data has been collected through
multiple field visits and semi-structured interviews. The findings of the study indicate that
organizations can improve the utilization of worn-out tyres by identifying tyre retreading defects
and their causes and by implementing corrective actions at different stages in the tyre
remanufacturing. According to cause-and-effect analysis, the defects found are failure of tread
due to lack of standard tread joint method, side bulge generation due to sidewall degrading, and
failure of the buffer layer due to tread and sidewall crack. Besides, a few recommendations are
made for tyre remanufacturing to increase productivity and minimize the defects generation in
retreaded tyres.
Keywords: Fishbone diagram, Pareto chart, Root-cause analysis, Retreading tyres defects, Tyre
remanufacturing.
1. Introduction
Tyre remanufacturing is an eco-friendly, sustainable and cost-effective method in which the worn-out
tyres are repurposed by applying new precure tread. Tyre remanufacturing increases the tyre life which,
in turn, reduces the environmental impacts of discarded tyres and hence, the process contributes to
sustainability and circularity [1]. Earlier, the worn-out tyres were disposed of using various disposal
practices such as stockpiling, burning, and illegal landfilling. These practices are still being used by the
majority of people which leads to serious environmental and health hazards [2]. Owing to these
hazardous impacts, academicians, policymakers, and practitioners have started looking into these issues
seriously. Many organizations, mostly small businesses, have started tyre retreading practices in order
to generate revenues from waste rather than minimizing environmental impacts [3]. In developing
countries such as India, tyre remanufacturing sector is still unorganized and there exists a lack of
standard process guidelines, thus, these organizations have developed their own methods of tyre
remanufacturing and recycling processes. Due to the lack of standardised process guidelines and other
challenges, the adoption of tyre remanufacturing practices is very low and the disposal rates are very
high. Majority of the existing processes are ineffective which results in poor quality, low life, and poor
performance of the remanufactured tyres [4,5]. To satisfy the expectations of the customers and to
popularize the use of remanufactured tyres, the remanufactured tyres must be more safe and durable,
have high levels of quality and capability of rendering better performance, which necessitates a clear
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Published under licence by IOP Publishing Ltd 1
International Conference on Advances in Mechanical Engineering-2022 (ICAME-2022) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1259 (2022) 012033 doi:10.1088/1757-899X/1259/1/012033
change in the existing tyre remanufacturing processes [6]. The efforts are needed to develop best
operational practices, standards and quality systems to increase the process efficiency and productivity
as well as to improve the tyre life in terms of safety, quality, performance and durability [7]. Besides,
more research is needed to examine and identify new perspectives for increasing the use of tyres for
remanufacturing rather than disposal. However, to achieve the above, there is a need to identify the
prevailing challenges of tyre remanufacturing process, pinpoint the defects in retread tyres and their
causes so that necessary actions can be taken to rectify the crucial issues [8]. In line with the above, the
present study has been carried out to investigate the challenges of tyre remanufacturing process and the
defects in remanufactured tyres as well as their probable causes [9]. The study has used following
methodologies: data collection through field visits and semi-structured interviews, brainstorming,
pareto chart and cause-and-effect analysis. The findings of study provides crucial managerial
implications that the top management should look forward to implement for the development of better
operations routines and an effective and optimized tyre remanufacturing process that could help in
eliminating the defects of remanufactured tyres and increasing their quality, safety and performance.
The remainder of this study has been organized as follows. Section 2 provides a brief overview
of the existing tyre remanufacturing process and the use of quality tools. The methodology adopted for
the study are described in section 3. In section 4, the analyses performed to achieve the objectives of
the research has been illustrated. Following this, the findings of the study are discussed in section 4. In
the end, the conclusions and the directions of future research are outlined.
• Primary Inspection: In this step, the worn casing, cuts, punctures, and other damages are identified
to decide the extent of retreading.
• Buffing: Buffing is performed to remove the outer layers of worn-out tyres using high-speed buffers.
More specifically, buffing removes the undesired or worn tread.
• Cleaning: After buffing, the casing of the tyre is cleaned using high pressurized air.
• Casing repair: In this step, the casing is inspected for the damages that need to be corrected. These
corrections are necessary to make sure that the quality of casing would remain within the acceptable
limits and the retreaded tyre would exhibit similar performance as a new tyre.
• Cementing: A temporary bond between the tread and casing is created in this step to prevent the
buffed surface from corrosion.
• Curing or mold curing process: After adding the layers of tread up to the required diameter, using
uncured rubber compound, the casing is placed into the mold. The molds are then closed and the tyre
body is filled to the right pressure. This casing is allowed to expand within the mold so that so that the
uncured material achieves the desired structure of the product along with the tread pattern [14,15].
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International Conference on Advances in Mechanical Engineering-2022 (ICAME-2022) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1259 (2022) 012033 doi:10.1088/1757-899X/1259/1/012033
be gathered and analysed from the process or system which is under scrutiny in order to produce a
Pareto Chart [17]. When the list of issues contains a mix of problems including both the issues with
potentially major repercussions and issues with minor consequences, one of the following two
approaches can be used, (i) the author weighting method to adjust count frequency, or (ii) frequency
analysis paired with a cost or exposure Pareto chart. The various versions of the basic Pareto chart are
routinely used in quality improvement approaches to identify the bulk of issues that may arise due to
small reasons [18].
2.3 Brainstorming
Brainstorming is a technique which is used for generating a large number of creative solutions and
innovative ideas for crucial problems that occur during the various stages of value creation and
distribution. Brainstorming is not a method for analysing ideas or creating ideas; nevertheless, its output
can be considered as an input to other quality improvement techniques such as the fishbone diagram
[19,20,21]. In this method, a group of experts, having different opinions regarding the subject of interest,
gather in a room and sit around a table to discuss and find all possible and valid solutions to the problem
at hand [22]. During the session, the suggestions and queries of all group members are catalogued in a
way that everyone can see them and, if necessary, modify them. To facilitate the brainstorming session,
it is preferable to adhere to the fundamental rules and explain them to the members. Furthermore, to
ensure the success of the meeting, the role of team leader in creating a friendly and comfortable
environment for the team members is crucial. The technique can be used for a variety of purposes,
including problem identification, determining causes and effects of a problem, and arriving at optimal
solutions with shared understanding of all the members of the team [23,24].
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International Conference on Advances in Mechanical Engineering-2022 (ICAME-2022) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1259 (2022) 012033 doi:10.1088/1757-899X/1259/1/012033
Table 1: A summary of literature on the use of quality tools and identification of defects
[29] Investigate and explain the tyre retreading stepwise process Fishbone diagram.
of cold and hot working and material properties of the
compound.
[28] Investigate the various factors affecting tyre retreading Bar chart.
brands and performance off retread tyres.
[31] Investigate the tyre retreading defect of fatigue growth Scatter diagram bar
crack rate generation in retreaded tyres. chart.
3. Methodology
The methodology adopted for this work is shown in Figure 1. The study began with the selection of the
tyre retreading process, i.e., cold retreading process. Further, data has been collected over a period of
four months (September 2021 to December 2021) through field visits and semi-structured interviews of
industry personnel. A total of 25 industries, located in Nagpur, Maharashtra, have been visited and 50
interviews have been conducted. During the data collection phase, the information regarding various
types of tyre defects and their causes and other important factors that play significant roles in the
assuring the quality and performance of retread tyres have been collected. Besides, a literature review
has been conducted to cross-validate the accuracy of the collected data. In the next step, the factors
influencing retreading process have been selected through the analysis of the data and literature review;
next, these factors are classified into the following categories, man, machine, technique, material,
process, and environment (Table 2). Following the categorization of factors, a fishbone diagram is
developed using all the valid tyre retreading factors (Figure 2). The various defects that occur in the
retreaded tyre are identified in the next step and a Pareto chart has been prepared to depict the severity
of defects (Figure 4). Using the output of the Pareto chart another fishbone diagram (Figure 5) is
prepared, containing the most severe defects. Following this, the root-cause analysis using the fishbone
diagram and brainstorming has been carried out to identify the major causes of the defects. Finally, an
action plan is prepared to improve the quality, safety, durability, and performance of retreaded tyre
(Table 3).
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International Conference on Advances in Mechanical Engineering-2022 (ICAME-2022) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1259 (2022) 012033 doi:10.1088/1757-899X/1259/1/012033
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International Conference on Advances in Mechanical Engineering-2022 (ICAME-2022) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1259 (2022) 012033 doi:10.1088/1757-899X/1259/1/012033
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International Conference on Advances in Mechanical Engineering-2022 (ICAME-2022) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1259 (2022) 012033 doi:10.1088/1757-899X/1259/1/012033
retreaded tyre. The other important defects include exposed ply, failure of the sidewall, failure of the
buffer layer, bulge, casing defects, and bead delamination.
The experts included a remanufacturing and planning supervisor, casing preparation worker, tyre
storage manager, quality worker, sales representative, and a representative of the factory manager who
was also the team's leader. In the brainstorming session, the team leader, first, explained the objectives
of the session. After that, the conversation regarding the essential process factors, tyre defects and their
causes has been started. The activity proceeded with a discussion of the group members' ideas and
suggestions, which they had written down on paper. In the final step, the conclusion, the final
evaluation, and modification (some identified sub-causes were deleted while others were added) have
been incorporated into the common solution. Figure 5 illustrates the fishbone diagram based on the
causes and sub-causes of tread failure.
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IOP Conf. Series: Materials Science and Engineering 1259 (2022) 012033 doi:10.1088/1757-899X/1259/1/012033
5. Discussion
The purpose of the present study is to identify the tyre remanufacturing process challenges and the
various causes of tread failure so that appropriate actions can be employed by the managers to improve
the above. To this end, data has been collected through industrial visits and semi-structured interviews
of industry personnel. The information collected is further used to develop fishbone diagrams and
Pareto chart. The identified challenges of tyre remanufacturing are classified into five sections, namely
man, machine, process, material, and environment. It has been observed that workers lack the process
knowledge due to the lack of specific training and therefore, they do not perform the work
systematically. The workers do not possess the knowledge regarding the different tyre defects, their
causes and the approaches to prevent the defects. The machines which are being used by the majority
of the industries are based on old technologies and need to be upgraded to ensure the production of
high-quality remanufactured tyres. The other significant observation related to machine includes the
lack planning for preventive maintenance, lack of proper mold design, poor curing rate due to the lack
of standard operating procedure, high energy consumption, and lack of calibration of tools and
instruments. Besides, the findings show that the firms do not focus on employing the crucial operational
practices such as inspection and testing of material quality and composition, developing standard
process guidelines for casing preparation, ensuring the effectiveness of process parameters such as
pressure, temperature, and time, developing standard procedure for minimizing loading and unloading
of tyres on machine as well as setup and changeover time, and implementing 5S methodology at the
shop-floor.
While investigating the tyre defects, it has been observed that tread failure is the most
prominent defect in a retread tyre which is followed by exposed ply failure of sidewalls, failure of buffer
layer, bulge, casing defects, and bead delamination. Among these defects, tread failure accounts for
39% of total tyre retreading defects. The majority of the firms follow their own tread joint procedure,
such as using high additive gum, bonding gum, and cushion strip in the joint area, and a few of them
apply staple pins to achieve better tread joints. The application of staple pins in the joint area is
extremely unsafe and leads to generation of most of the defects in retread tyres. The fishbone diagram
(Figure 5) illustrates the various causes of these defects which could be beneficial for managers in
deciding how to control the occurrence of these defects. Overall, the use of quality tools reveals that
one of the most important reasons for the defects is the lack of standard process guidelines regarding
tyre remanufacturing which have led these firms to develop their own work procedure. These
procedures are mostly faulty as the firms do not have the required skilled personnel, advanced
technologies as well as the innovative mindset.
In addition to the above, a list of action plan is formulated to minimize the defects and to
mitigate the process challenges which is presented in Table 3. As the pollution is increasing day-by-day
and the hazardous impacts of environmental deterioration are now becoming visible in the form of
changing climatic conditions, weather pattern, losses of flora and fauna, and various diseases, it has
now become imperative more than ever for everyone to look for ways to minimize the resource
consumption, pollution, and carbon footprint. The adoption of tyre remanufacturing business approach
could be one of the most effective means to achieve the above. Using tyre remanufacturing as a business
strategy one can generate revenue from wastes, however, the process the not that simple as it needs
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International Conference on Advances in Mechanical Engineering-2022 (ICAME-2022) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1259 (2022) 012033 doi:10.1088/1757-899X/1259/1/012033
a lot of efforts in terms of resources and time. Hopefully, the findings of the study would help the firms
to move ahead towards the implementation of an effective system for tyre remanufacturing.
6. Conclusions
The present work highlights the significant challenges of tyre remanufacturing and classifies them into
different categories that could be used by the managers while looking to overcome the impediments. In
addition, the most prominent defects and the reasons for their occurrences have been identified and a
comprehensive list of plans of action has been provided which could provide necessary insights to the
managers while developing a roadmap for the development of high quality and high-performance
remanufactured tyres. The use of quality tools including the Pareto chart and fishbone diagram has
provided a clear picture of the current situations as well as the actions that can be taken to improve
them. Hopefully, the present work would prove beneficial for the firms to adopt and excel in the tyre
remanufacturing business.
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IOP Conf. Series: Materials Science and Engineering 1259 (2022) 012033 doi:10.1088/1757-899X/1259/1/012033
Acknowledgement
This work has been conducted under the Center of Excellence Flexible manufacturing system/ Robotic
Design, G H Raisoni College of Engineering Nagpur India. The authors are also thankful for the support
provided by the organisation Bharat Tyre Retreading Works Nagpur, India.
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