Tire industry

Providing individual solutions engineered to improve customers’ material flows is one of Pesmel’s strengths. As a total system supplier, we take overall responsibility for the project from pre-engineering to handover. Planning starts with defining the needs of a functional layout, material flows between processes, requirements for the finishing area, and alternative routing for exceptional situations.

We build a simulation model to design, develop, optimize, and validate our logistics systems. The model acts as a guidance for implementing a fully functional and optimized system. It enables pre-construction testing and verification of large and complex systems.

The simulation process creates a digital twin, which is a virtual representation that serves as the digital counterpart of a physical process. Our digital twin is proven to be usable tool in commissioning and development of customer’s material flow solution.

A digital twin is also used in daily operations such as continuous optimization of automated storage, estimation of near future occurrences, and support for operator decision-making. It also plays an important role in planning and executing aftersales operations including data collection of equipment usage, preventive maintenance, and virtual testing of software updates.

Pesmel has developed a completely new, intelligent warehousing system for the tire industry. The key features are operation without pallets, reduction of storage footprint with high storing density, sorting at in-feed, a combination of storage and order picking, and simple layout with a minimal amount of equipment. The idea is to arrange production and material flows so that efficiency is maximized, and needed equipment minimized. The solution uses only four components to fully automate in-mill logistics and storage: a conveyor system, racking, stacker crane(s), and robots.

The storage solution is based on high-bay technology, where the tires are stored vertically on racks without pallets. The height of the storage can be 35m, with more than 30 levels and 9-20 individual tires per storage location. High-bay storage gives a footprint reduction of 45%, with a higher storage density than traditional solutions using pallets.

Growing customer demands mean that efficient and smooth in-mill logistics offer tire manufacturers significant competitive advantages. With added intelligence for storage, sorting, and distribution functions, tire facilities can create a powerful and dynamic distribution center that opens opportunities for improvement all the way up to strategy and business models.

Storing and order picking is combined and done in the storage area, which greatly improves warehouse logistics, and reduces the time spent on shipping tires. The picking and dispatching time is reduced to one-third of that of a traditional warehouse.

The high-bay storage technology has proven to be flexible and efficient as it enables an increase both in outbound orders as well as in in-storage space, which is a major benefit when it comes to seasonal variations. The high-bay storage units help with peak demand periods the mills experience, as every tire in the storage is accessible and ready to be shipped. Another real benefit is that the system stores individual tires and not a whole pallet load or cages, which means just one specific tire or tire set is taken from the warehouse as needed instead of the entire load. A high level of automation also ensures error-free deliveries, which greatly improves customer satisfaction.

Pesmel’s Material Flow How® concept includes equipment integration, material flow management, and information flow management. A full control system enables integration of the various functions contained within the mill into one logistical entity.

Full material handling control means zero damage and no lost products or delivery errors. The entire system is managed by a centralized control system which tracks and tasks the products from arrival to departure. Real-time inventory control significantly supports production planning – a critical area in terms of cost savings.

A state-of-the-art mill needs a modern control structure. Our system integrates all levels of production and logistics control, from electrification to automation, monitoring, material flow planning and management, and logistics into one full chain using a comprehensive user-friendly platform.