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Manufacturing such a wide range of diverse products requires efficient processes , as Arnab explains : “ Automating a lot of our processes not only enhances our overall efficiency but also minimizes human error . For example , we have mapped out the entire flow of steam and air inside the plant , and we have found a mechanism to detect leakages which can be acted upon immediately . Before this , there were losses that we wouldn ’ t have been aware of and that were very difficult to detect and locate . A lot of time was wasted in diagnosing the problem . Now we can identify the problem and solve it on the spot .
“ Another example of automation is the processing of materials . We buy in a lot of natural rubber , and , as with any natural product , the quality can fluctuate . We have developed algorithms which identify the incoming raw material parameters and adjust the product processes automatically so that the optimum quality is delivered at optimum cost .”
Arnab then highlights how the business ’ younger gen-z and millennial employees have played a central role in this process . “ With a lot of these Industry 4.0 applications gaining traction , these employees have proven to be very fast learners . When we identify a problem , they are excellent at finding a solution . This has resulted in vast savings in energy costs , scrap reduction , and decreased water consumption , making our plants more efficient and effective .”
The focus on improvement goes beyond just operational benefits but significantly contributes to the company ’ s sustainability targets as well , with specific measures deployed to improve manufacturing processes . “ By 2030 ,” Arnab says , “ we want to reduce our carbon footprint by 50 percent . When we made this decision , we began in earnest by taking several actionable steps . Our boilers , for example , which produce steam , are adaptable to biofuel . Currently , 35 to 40 percent of our plants ’ energy needs are met through renewable sources . One of the other big factors in this industry is the product itself . By constantly improving the rolling resistance of our tires , we reduce
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