CEAT LIMITED
CEAT is the flagship company of the Rs 22,000-crore RPG Enterprises. It was established in 1958 and is currently one of India’s leading tyre manufacturers with strong global presence. It produces over 15 million tyres a year and offers the widest range of tyres to all segments. It manufactures world-class radials for: heavy-duty trucks and buses, light commercial vehicles, earthmovers, forklifts, tractors, trailers, cars, motorcycles and scooters as well as auto-rickshaws.
CEAT’s Halol manufacturing capacity contributes over 7 million tyres produced by CEAT worldwide. The entire plant in automated and driven by a combination of software and hardware by South Korea based automation experts utilizing Oracle Database in the backend. CEAT’s challenge was difficulty in getting support from South Koreans. They desperately needed a local partner who could help them in terms of troubleshooting, upscaling, streamlining and performance improvement. Lack of proper support was resulting in progressive downfall in production at the manufacturing unit.
Approach
Solutions Architects from BeyonData found this challenge unique and exciting. The complete automation was heavily dependent on Oracle systems but it had not been maintained for many years and was now a serious bottleneck.
A team of software experts, techno-functionals and database experts had multiple rounds of meetings, visits at the plant to understand the data-flow process thoroughly and unravel dependencies to connect right dots.
Proposed Solution
Team BeyonData came up with solution that was a combination of infrastructure upgrade, software upgrade, architectural changes in existing infrastructure
They even worked closely with South Korean team to identify bugs at application level and provided development support to CEAT to improve performance and streamline data flow between various application platforms to smoothen the operations
Outcome
5x Performance Improvement
80% reduction in outages due to IT Infrastructure
Increased Production from 16K tyres per day to 18K tyres per day (12.5% increase in productivity)