Modern Process Management for Industrial Tyre Retreading

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The economic software solution for the modern retreading of commercial vehicle tyres

Modern tyre retreading companies are becoming

more and more a part of international acting

service organisations dealing with the tyre

management of fleet vehicles. This has resulted

in high expectations such as a high product

quality while the price pressure is constantly

increasing, a quickest possible delivery time and

the capability to react in a flexible way. Facing

all that and at the same time securing and incre-

asing market shares requires integrated system

solutions!

Clearly focusing on the requirements of the tyre

retreading industry, fa/r offers a high-perfor-

mance solution which:

Offers a practice-oriented representation and

support of the company-specific production

processes

Is highly accepted by its users

Is very user-friendly

Is fast to implement

Is easily integrated into an existing system.

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What you gain with fa/rRecognise the sign of the times and optimise your processes by utilising fa/r!

Our long-term experience in the field of soft-

ware for the tyre retreading industry and the

consideration of our customers’ requirements

and experiences guarantee the suitability of our

retreading program in practice. Decreased administrative costs, even

with increasing production, due to total

process monitoring and process control

Process optimisation based on real long-

term data

Productivity increase due to automation

Trouble-free interchange of staff

members during the production process

and reduced error risk due to machine

interfaces and defined rules

Reduced production costs due to efficient

deployment of staff and material

Optimised material stock due to integra-

tion in supply chain systems

Shorter processing times, high product

quality and a transparent production

process increase customer confidence

and strengthen existing customer

relations

Automated data exchange with tyre trade

programs prevents media breaks and

multiple data capturing

Increased quality awareness of the

staff due to detailed production

documentation

Individual reports and statistics enable

detailed evaluations

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Seamless integration of production, warehouse and office

fa/r controls and documents the production of

retreaded commercial vehicle tyres, in both cold

and hot retreading processes, from the reception

of the casings up to the delivery of the finished

tyre. Based on memorised process data, fa/r

enables the regular optimisation of processes

within the retreading factory.

The seamless integration of all relevant company

domains firstly ensures the availability of all

process information, and secondly enables

centralised process monitoring and control.

fa/r functions:

Planning and control of production

orders in pre cure and mould cure retrea-

ding processes

Dynamic data management, situation-

related data disposition and capturing

Automated control of modern processing

machines

Complete production documentation

Logistics support due to mobile data

capturing

Material disposition with integration in

supply chain systems

Extensive statistic evaluations and

reports

Electronic data exchange with tyre trade

systems

fa/r functions in administration,

production and warehouse

pre cure and mould cure retreading processes

grinding

tread cutting

building

autoclave

final inspection

delivery labels

casingreceipt

initialinspection

warehouse labels

buffing

repairing

building

measuring

presses

office warehouse

data exchangetyre trade

fa/r application and database

service

LAN, WAN, internet

casing account

casings,treads, finished tyre

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Flexibility and Scaleability due to Modularity

Due to its modularity and scaleability in connec-

tion with extensive adaptive features, fa/r can

be adjusted to different user environments and

grow with changing requirements. After setting

up a start configuration the system can, accor-

ding to the needs, be extended in its depth (new

stations) or in its functions (new modules). Many

data interfaces assure the communication with

existing IT applications (tyre trade), ERP systems

of material suppliers and processing machines

and lines.

Computer-aided production

control for the tyre retreading

industry with the modular

fa/r system

The characteristics of fa/r are:

Perfected functionality

Useful modularity

High scaleability

Fast implementation

statistics

casing account

software interfaces

(ERP)

process data recorder

fa/r production

fa/r basic

machine interfaces

complaints

handheld

warehouse

fleet management

interface

supply chain interface

presses data

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fa/r basic

Basic ModuleSecured data basis, clear rules, flexibility due to parameterisation

The fa/r basic module contains the central data

for the entire system. Extensive functions assure

the adaptation of the system to the operative

processes of the retreading factory.

Basic data administration (clients,

suppliers, tyres, treads, text blocks,

staff, process codes…)

Parameterisation, settings

Rules, plausibility checks

Rights administration

Order control, delivery

Items on stock

Order department

Production documentation

fa/r Basic Module

Plausibility checks, established user rights and

clear rules guarantee an economic utilisation of

the solution.

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pre cure and mould cure retreading processes

grinding

tread cutting

building

autoclave

final inspection

delivery labels

casingreceipt

initialinspection

warehouse labels

buffing

repairing

building

measuring

presses

pre cure mould cure

fa/r production

Production ControlFar-sighted and on the right track

Production planning

Allocation and gathering of relevant data

at the production stations

Automated data exchange with machines

and lines

Integrated rules for defined reactions to

special situations

- Tyre resetting

- Casing failure or quality degrading

- Change of treads

- Change of moulds

Automated material administration

Foreman function for monitoring and

control

Production control, which is the heart of the

solution, receives information in real time from

the production process in order to provide the

production manager at all times with an exact

process overview and hence allow for fast and

Computer-aided production control in pre cure and

mould cure retreading processes with fa/r

secure planning and control. The production

manager is supported by rules which are adjusted

to the user‘s requirements and saved within the

system.

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Additional ModulesCompleted functionality!

Additional modules complete the fa/r basic func-

tionality and allow for the configuration of a

client system according to the real requirements

of the tyre retreading factory.

With requirements changing, all additional

modules can be retrofitted and used. This enables

the fa/r installation to grow with the require-

ments of the retreading company.

Automated data exchange with programs from the areas tyre trade and financial accounting

Client and order data are transferred to fa/r from the tyre trade

fa/r sends order-relevant production data back for invoicing

Consistent master data

Seamless integration, without media break, fast, faultless

software interfaces

(EPR)

Preconfigured evaluations, based on

memorised production data

Variable selection criteria

statistics

Mobile station for special areas such as

EM retreading, heat presses, warehouse

areas

Online or batch processing

handheld

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Fast and flexible handling of clients‘

casings and retreading orders

Organised according to make, dimension,

category

Cyclic account balancing

casing account

Exact complaint processing with auto-

matic access to all production data

Location of credit notes and technical

data

Examination of weakest points based on

real process data

complaints

Capturing of the presses data (heating

time, mould and bellows change, heated

tyres) by aid of a handheld and transfer

to the production database

presses data

Inventory maintenance for casings,

treads and produced tyres (warehouse,

storage place)

warehouse

Modularity brings sustainability:

The continuous development of new

additional modules, mostly based on our

users‘ ideas, mirrors the growing

functionality of fa/r.

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Machine InterfacesConsistent Automation!

The trend towards industrial tyre retreading

comes along with an increased use of automatic

machines and lines in the production process. In

order to fully use this potential fa/r offers data

interfaces, which minimise and facilitate easy

manual operations, exclude data input faults,

increase the rate of machine utilisation and take

over process data.

machine interfaces

ShearographyCompletion of the tyre documentation by

adding test pictures and results

Marangoni SFERA

SDS ITT

Bandag ��00 INSIGHT

BuffersAutomated transfer of the retexturing

program and back transfer of retexturing

and process data (buffed circumference,

buffed width, process time)

Bandag ��10E, ��10E

Collmann RM��

Matteuzzi RAS�0-DC�

Marangoni BlueDart

Builders

Automated transfer of the building program

and the casing and profile data

Bandag �10�E, �10�E

Bridgestone baz �1�0

Autoclave recorder

Completion of the tyre documentation by

vulcanisation data (pressure, temperature,

time)

Ellerbrock, Bandag EPC

Current automation interfaces*

* Further machines and lines can be integrated if required. Pre-

set: Shearography (Steinbichler, t.r.m.) • buffers

(Marangoni, SIO, t.r.m.) • builders (Matteuzzi, A-Z, t.r.m.)

• autoclave units (t.r.m.)

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Module Process Data RecorderWith fa/r always up to date and on the right track!

process data recorder

The integrated process data recorder in fa/r

provides the data basis for process analyses

directly from the production process.

Real process data provide the basis for

process analyses and show optimisation

potential

Productivity evaluations

Product hit list

Efficiency evaluation of automated

machines

Evaluation of cycle times, turnaround

times of tyres and orders

Evaluations of “problem tyres”

Recognition and evaluation of seasonal

stock movements

Recognition of weakest points and deve-

lopment of reserves

Rate of machine utilisation

- Total running time

- Productivity progression

- Utilisation frequency of given programs

- Set-up time compared to working time of

automated machines

Personnel statistics

- Staff-related

- Between shifts

- Between factories

Product-specific process data

Work time per tyre

Lehmann Mertens Bauer

Example for collected process data

Station Rauher

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Supply Chain Interface The rolling warehouse!

Modern industrial order and supply systems

feature automated and custom-made order

processes and just-in-time deliveries. The supply

chain interface allows for the integration of

retreading companies in supply chain manage-

ment systems of material suppliers.

supply chain interface

Reduced bound capital for the mate-

rial warehouse of the retreading factory

(rolling warehouse)

Automatic ordering considering order

need, warehouse and disposition stock

Adaptation of discount steps

Automatic update of material

master data

- Integration of new profiles

- Order ban on profiles being phased out

- Production ban on profiles

Electronic delivery note in order to

facilitate material reception

Transfer of manufacturer‘s information

on profiles

delivery material update

ERP system of the supplier

order

Integration of the fa/r system in individual order and

delivery systems

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Computer-aided Tyre Retreading User Benefit

As an organisation and control tool within the

retreading factory, fa/r considerably increases

the work efficiency at all company levels, from

the managing director over the works manager

down to the production, administrative and

warehouse staff!

Productivity increase Increase of the rate of automation of

modern machines due to machine

interfaces

Online information

Fast and faultless identification of

casings and retreaded products

Electronic data exchange with traders

and suppliers

Cost-cutting Reduced administrative effort

Reduced warehousing costs due to dispo-

sition and order-controlled integration

into supply chain-systems

Optimised line and staff deployment

Avoiding cost drivers

Quality Assurance Improved quality awareness of the staff

due to detailed documentation

Defined rules and plausibility checks

decrease failure risks

Machine interfaces ensure quality

standards

Better customer satisfaction Shortened delivery times due to

reduction of cycle times and optimal

material disposition

Improving product quality means less

complaints

Auto-information system for traders

Exact treatment of scrapped casings and

complaint management

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Improved flexibility Order planning based on customers‘

orders and warehouse production with

regard to material and dispo stocks

Facilitated handling due to utilising the

casing account

Machine interfaces reduce staff require-

ments and support the trouble-free

interchange of staff

Automatic documentation Support of quality assurance systems

as well as ISO �00� and ECE 10�

certification

Proof of all production information at

integrated stations

Extensive evaluations and reports in

order to measure and prove experiences

Process optimisation Real process data provide the data basis

for valuable productivity evaluations on:

- Staff

- Shifts and factories

- Products

- Machines

- Material flow

and enable a continuous process

optimisation

Computer-aided Tyre Retreading User Benefit

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Modern Software Solutions for the Tyre Market

Modern vehicle fleets require an impeccable

tyre management in order to maintain their

hold on the market. All partners participating

in the product “tyre retreading“, from mate-

rial suppliers to machine manufacturers to tyre

retreading factories to service points, are faced

with high requirements.

Our modern and practice-proven software solu-

tions support market participants of all levels in

efficiently organising their business processes,

from the material delivery in supply chain

systems to the control of the retreading process,

to the optimisation of the machine park mainte-

nance to the complete fleet management.

Production control of retreaded commercial vehicle tyres

Central maintenance management and optimisation of machines and lines

Modern management of commercial vehicle fleets including tyre manage-ment

Contact

PC-Soft GmbH

Adolf-Hennecke-Str. ��

D-01��� Senftenberg

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email info@pcsoft.de

web www.pcsoft.de

Sales Office Rhein-Main

Kurt-Blaum-Platz �

D-����0 Hanau

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