From lab to the road: Achieving ~20% faster time-to-market and complete product traceability PLM-based tyre production

A leading tyre manufacturer overcomes siloed data and processes with a highly customised Product Lifecycle Management (PLM) implementation for end-to-end collaboration and traceability

Industrial Manufacturing

Challenge:

Our client grappled with siloed data, resulting in poor collaboration across different teams, suppliers, and retailers. Their complex data management structure further strained the successes of global projects and integration between various business functions. To enhance their tyre quality, the client sought real-time and historical data analysis for establishing KPIs, dashboards, and reports.

Solutions used:

  • End-to-end PLM implementation (maturity level 4) for a single source of truth
  • A smarter New product development (NPD) process to diversify product offerings and accelerate innovation and rollout
  • Deep-dive business process consulting to boost supply chain efficiency through unified raw material management and supplier collaboration within an active workspace environment
  • Teamcenter infrastructure assessment for enhanced process engineering and collaboration
  • Data modernization for enhanced security, better scalability, and reduced costs

Tech stack

PLM

Teamcenter

Bosch PLM consulting

Digital Twin

Impact

20%
accelerated
time-to-market
15%
reduction of design
cycle time to production
Feedback loop for
data-driven testing
Improved revenue
growth of €78.74 billion

Business problem

Immersive Journey

As the demand for connected and smarter vehicles grows every day, building adaptive, sustainable, and high-performance tyres becomes a strategic imperative. With the varying and intricate needs of the modern customer – the ‘delight factor’ revolves around unique features such as exceptional cabin experiences coupled with enhanced tyre designs capable of handling higher torque, regenerative braking, improved rolling resistance, lower fuel consumption, and a quieter ride. To meet them, tyre manufacturers must prioritise faster cycle time, superior design, transparent processes, centralised data, and improved communication across teams and suppliers.

Teeming with identical goals of driving innovation, a large tyre manufacturer, however, grappled with siloed engineering and R&D data and processes. This led to lower supply chain visibility, inaccurate reports, and hindered informed decisions, as well as interactions with remote branches and suppliers. The client sought to maintain an edge through data analytics to set strong KPIs and create effective dashboards to improve decision-making. The firm also looked forward to accelerating the development cycle, minimising costs, and increasing scalability in order to increase competitive advantages.

Bosch SDS in action

Bosch SDS’s team of industrial experts gained a deep understanding of the client landscape and came up with a two-pronged approach embedding data and digital engineering. The first step was comprehensive business process consulting, and the second – reimagining the entire business model. Leveraging our seasoned process expertise, we recommended an end-to-end PLM transformation (aiming for maturity level 4), redefining their tyre production processes.

We drove the client’s modernization journey by creating a single repository, meeting compliance standards, and enhancing product quality with the following steps:

Teamcenter infra-assessment for automated and streamlined product lifecycle processes to increase visibility, and cross-team/ cross-functional collaboration.
Leveraged Digital Twin to boost the performance of physical products through machine learning (ML) capabilities and multi-physics simulation, generating valuable insights by depicting how the product functions under varied circumstances.
Leveraged MBSE-based multi-domain product development platform with data-driven metrics on cost, reliability, and manufacturability.
Superior visualisation and digital mockup capabilities through 2D/3D design data with JT technology.
Smarter PLM-powered informed decision-making through historical data and real-time updates from IoT devices and sensors for continuous product improvement.

Shaping timeless impact

Through our well-designed consulting strategy and a smarter approach to digitalisation modernization, we enabled our client to elevate their tyre quality by adopting a data-driven, testing-based approach. The client was able to take complete charge of their data and processes, elevating their end-to-end product portfolio design and development—from inception to disposal.

Minimised the design cycle time by 15% from ideation to production, accelerating time to market by ~20%

Reimagined the NPD process for all product portfolios

Achieved end-to-end traceability for the complete set of products

Introduced a feedback loop for test lab data management

Reduced time, effort, errors, and costs

Improved service operations

Helped achieve higher quality products

Enabled higher business profitability

The Bosch SDS edge

Immersive Journey

With our specialisation in bridging the gap between processes, tools, and people, Bosch SDS elevated the client’s data governance and operational capabilities. This led to enhanced tyre quality, increased flexibility, and agility at scale for impact-focused growth in their business.

Immersive Journey
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