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JK Tyre: Driving production intelligence across tyre manufacturing

Altizon DFX becomes a real-time digital system of record, optimizing various processes like mixing, calendering, and cutting and reconciling production output with ERP.

Altizon’s impact

8–10%

productivity improvement on connected lines

5%

improved quality through process analytics

Real-time ERP integration for dynamic planning and scheduling

The Challenge: Production inefficiencies and invisible process gaps

JK Tyre operates highly process-intensive manufacturing environments across multiple plants, supported by a mix of OEM systems, control platforms, and partial MES deployments, which led to gaps in visibility, reliability, and operator adoption.

No production visibility

Plack of real-time tracking: Without a digital system, there was no way to track productivity or output across mixing and curing in real-time.

Paper-based data issues: Production and downtime were recorded on paper logs post-shift, leading to significant data inaccuracies and reporting delays.
Invisible loss patterns: The absence of a digital interface meant operators couldn’t tag downtime causes, making root- cause analysis (RCA) impossible.

Reactive decision-making: Management relied on day-old, fragmented reports, preventing any proactive intervention on the plant floor to improve performance.

Limited process insights
No live parameter trending: Critical variables—including temperatures, pressures, and cure times—were not monitored,leading to undetected process fluctuations.

Lack of automated SPC: Without automated Statistical Process Control (SPC), there was no way to identify process drifts before
they resulted in scrap.

Delayed quality feedback: Quality teams relied on manual post-batch testing, meaning defects in mixing or calendaring were only caught after significant value was added.

Reactive quality interventions: The absence of a digital logic layer forced a “inspect-in” quality model rather than a “build-in” quality approach to improve performance.
Delayed ERP synchronization
Manual inventory booking: Production and raw material consumption was recorded manually at shift-end, leading to 8–12 hour lags in inventory accuracy.
Lagging planning inputs: Scheduling and procurement decisions relied on outdated, day-old data, causing suboptimal planning.
Inaccurate order accounting: Manual reconciliation led to inconsistent loss reporting and delayed order closures, complicating financial accounting and mass-balance accuracy.
Operational blind apots: Without automated data reconciliation, there was no way to correlate real-time production status with accurate inventory accounting.

JK Tyre needed a stable, scalable digital platform that could unify plant -floor data, support operators, and integrate seamlessly with ERP.

The solution: Creating a reliable, real-time digital layer across critical processes

JK Tyre implemented Altizon’s Digital Factory Platform across high-impact assets—starting with mixers, calenders, and cutters—to establish a dependable digital foundation for operations, analytics, and future scale.

Production performance
  • Live data from mixers, calendars, and cutters streamed directly into the platform.
  • Operators viewed real-time dashboards for output, losses, and cycle adherence.
  • Downtime codes and reasons were logged instantly at the line through intuitive operator screens.
Outcome:
  • 8–10% productivity improvement resulted from faster corrective action enabled by real-time visibility into shop-floor losses.
  • Key process parameters such as TCU zone temperatures, ram pressure, and batch energy were tracked in real time.
  • SPC and Cp/Cpk analytics detected process drifts early.
  • Automated alerts notified operators when parameters crossed control limits.
Outcome:
  • Maintenance and quality teams intervened earlier, reducing MTTR and preventing mixing and curing defects.
  • Manual end-of-shift reconciliation was replaced with real-time, automated ERP integration.
  • In-process inventory data synced continuously to support dynamic production planning and scheduling.
  • Improved alignment between shop-floor execution and planning systems.
Outcome:
  • Faster order closure, more accurate loss reporting, and improved reliability of production and inventory data.

The transformation: From plant -floor blind spots to process intelligence

Before Altizon
After Altizon
Outcome
Production visibility
Manually tracked
Real-time OEE and loss dashboards
8–10% productivity gain
Process control
No parameter trending
Live SPC framework with alerts
5% quality improvement
ERP integration
Manual booking after shifts
Automated, bi-directional ERP sync
Accurate inventory, improved planning and scheduling
Standardization
Plant-wise variations
Unified digital architecture
Common benchmarking across plants

“Altizon’s platform is the single source of truth for monitoring our operational KPIs and continuous improvement initiatives.”

— Mr. Anil Makkar, Manufacturing Director, JK Tyre

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