Manufacturing · MFG-01
Operational Excellence in Vertically Integrated Tread Rubber & Molded Goods Manufacturing
Business challenge
The client required structured operations oversight and process standardisation across its vertically integrated rubber manufacturing value chain, spanning from processing scrap tyres into reclaim rubber, converting it to customized rubber compounds, and molding it into tread rubber. The objective was to improve production efficiency, supply chain discipline, R&D coordination, maintenance planning, performance visibility, and product costing accuracy.
What we did
Mapped the end-to-end rubber value chain from scrap tyre processing to reclaim rubber, customized rubber compounds, and tread rubber manufacturing.
Reviewed and redesigned business processes across purchase, production, inventory, quality control, dispatch, sales order processing, R&D, and maintenance.
Created a structure and data-driven workflow for rubber compound R&D with a centralized Design of Experiments (DoE) framework.
Defined SOPs, roles, responsibilities, data capture points, and review mechanisms for key departments across the manufacturing value chain.
Designed performance metrics and benchmarks to monitor production efficiency, yield, material flow, quality performance, maintenance effectiveness, dispatch reliability, and sales order fulfilment.
Developed a product costing framework covering cost drivers, cost components, standard cost estimation, and stage-wise cost visibility.
Implemented and institutionalised performance tracking through shop-floor boards, daily cadence, and accountability roles.
Audited the current ERP system for manufacturing fit and function, comparing software capabilities against shop-floor realities and recommending required configurations and customisations.
