1. 1
INTRODUCTION
Primavera P6 is a database system that codes and records logic networks on large projects. It keeps
track of the agreed-upon project contract dates. Primavera P6 is the most widely used engineering
and construction planning and execution tool due to its powerful critical path analysis and
customizable coding structure.
It is used for project planning, management, and execution. It is intended to handle both large and
small projects in a variety of industries, including construction, manufacturing, energy, and
information technology. It has been doing so for over 30 years in projects all over the world.
Primavera P6 can be traced back to 1983, when it was first established as Primavera Systems. It grew
in popularity over the next 15 years. By the late 1990s, advances in server technology had compelled
the company to divide Primavera systems into two software versions: a desktop application (favored
by contractors, suppliers, and manufacturing firms) and a web-based enterprise option.
Primavera P6 offers features are as follows:
o Time & Schedule Management
Time and Schedule Management is an extensive concept that includes the basics of project planning
and scheduling. From this concept we can analyze the Critical Path Analysis, understand calendars,
total float, and constraints at this stage. Then, insert activities, determine activity durations, and
assign relationships to create the CPM Chart of the project.
o Resource Management
A project cannot be performed without assigning labor, manpower, and equipment resources. We
determine our project’s resources and classify them. Then, assign resources to the activities and get a
resource loading histogram. Finally, analyze over allocations and try to level over-allocated
resources.
o Cost Management
Without a proper cost management system in place, a project cannot be completed on
budget and the organization can easily lose funds. Primavera P6 enables to track and
manage project costs effectively. In Primavera P6, we assign expenses to our project
without using resources. We can use top-down budgeting methods and analyze cost
loading charts that Primavera P6 software will provide for our project.
o Activity Coding
Activity coding should be one of the most important lessons in any Primavera P6 Training
Programme. First of all, we learn the process of creating and assigning activity codes as well as
learning activity code settings. Understand how to use the activity codes for grouping, filtering,
importing, and exporting purposes. Activity coding enables us to make changes to the project
schedule using the global change feature.
2. 2
o Assigning and Maintaining Baselines
The performance of a project or activity can not be tracked and reported effectively without
assigning and using baselines. A project baseline consists of schedule, cost, and scope that enables us
to evaluate the performance of our project over time. We learn the differences between project
baselines & user baselines in Primavera P6. Create and update a baseline for our project and evaluate
our project’s performance against the baseline. Finally, we create reports that include both planned
and actual figures.
o Updating
Progress updating is one of the most important concepts in project controls. Here we understand the
percent complete types and progress different types of activities such as Level of Effort and WBS
Summaries.
There are some update parameters involved in the project schedule updating process such as
Duration Type, Percent Complete Type, Rules of Credit, and Progress Calculations. Each parameter
has typical functions and calculation methods. We can also use Excel to update our Primavera P6
schedule.
o Importing and Exporting
All project data is stored in the Oracle database. Primavera P6 allows us to import and export various
data, excel sheets, projects, and baselines while revising, updating, or creating a new schedule. We
can also import a project by using XML files.
OBJECTIVE
Scheduling a project: a one-story concrete office building with an area of about 4,000 square feet
(SF) per floor. The floor has a slab on a grade (SOG), carried by both concrete columns and concrete
masonry unit (CMU) walls. The roof is made of wood trusses topped with sheathing and asphalt
shingles. The schedule logic includes many simplifying assumptions.
SCOPE OFWORK
The scope of Primavera is an ever-changing, ever-growing tool giving unparalleled control,
monitoring, and insight to planners, employers, stakeholders, and anyone who is involved in given
project for making activities and tasks easier to complete.
Key Features of Primavera Software
Given below are some of the key features of Primavera Software:
Scheduling
To ensure that the schedule is filled in appropriately, Primavera P6 includes an array of scheduling
alerts and reporting tools, resulting in keeping the project on schedule and within budget.
3. 3
Risk and Opportunity Management
Project Managers can easily identify when risks may occur, and the impact of these risks in the
project’s baseline and schedule. Initial and recurring risk is conducted by project managers and
opportunity analysis is done within the schedule.
Resource Management
Uses of resources can closely be monitored by Project Managers within Primavera P6 and generate
forecasts of changes in resource availability. To keep the project on track, project managers identify
what other resources may be diverted within Primavera P6. ERPM users can transform raw data into
easily understandable and shareable graphics by taking advantage of the visualization tool.
Contract Management
Organization can keep control over multiple projects or programs with the help of Primavera. Project
Managers can copy information from the Oracle database in seconds when a new project closely
mirrors a previous project.
BASIS OFSCHEDULE (PROJECTWORK)
The general contractor (GC) will be doing mainly the structural work, using his/her
own work force, but he or she will use the following subcontractors for other work.
Section 1: Creating Project’s Baseline:
1. Create the project with the title “Office Building-01” and ID “OB1”. Enter the specified start
date. Define the required calendar. Add the given responsibilities and area codes.
2. Enter all the activities listed above, along with their information (duration, relationships, lags,
etc.).
3. Create the resources and assign the required units for each activity.
General Guidelines
The work will be mainly on the computer. Some written parts may be required. Make sure the
reports are marked clearly with your name, the date, the report name, the page number, and so forth.
Write down any assumptions made.
Use Primavera P6 Professional R17 software.
Consider the following calendar: 8hrs/d, Friday is off, Saturday is the start of the week.
The project starts on December 19, 20216.1US Dollars = 74.79 Indian Rupees
4. 4
Work Packages
The general contractor (GC) will be doing mainly the structural work, using his/her own work force,
but he or she will use the following subcontractors for other work.
Nick Name Full Name Type of Work
ACA All Seasons AC & Heating HVAC
WAL Wall to Wall Drywall, Stucco and Paint
MAR Master Art Landscape Site work and landscaping
MAS Mase & Company Masonry
ROS Ross Carpentry & Framing Wood Framing
PLM Plumbing Experts Plumbing
RAB Rabbit-the-Roofer Roofing
TAC Tile and Carpet Co., Inc. Flooring
WIN Windows & Doors NT Doors and Windows
ZAP Zapp Electric Co. Electrical
List of Activities
Three areas are designated in the project: ALL (all of the project), 1ST (first-floor activities),
and ROOF (roof activities).
Activity
ID
Activity Title
Duration
(Days)
IPA
Rel.
Type
Lag
(Days)
RESP Area
1000
Notice to proceed
(NTP) *
- - - GC ALL
1010 Mobilization 3 1000 - GC ALL
1020 Clear & grub 12 1010 - GC ALL
1030 Excavation 7 1020 SS 4 GC ALL
1040 Foundation 15 1030 SS 3 GC ALL
1050 Fill, compact, and
treat soil
3 1040 - GC ALL
1060
1st floor plumbing
roughing 3 1050 - PLMX 1ST
5. 5
1070 SOG 4 1060 - GC 1ST
1080 1st floor columns 7 1050 - GC 1ST
1090
1st floor external
CMU walls 10 1070 - MASE 1ST
1100
1st floor internal
CMU walls 14 1070 - MASE 1ST
1130 1st floor electrical
rough-in
4 1090, 1100, 1280 SS 2 ZAPP 1ST
1090, 1100, 1280 FF 2 1ST
1140
1st floor HVAC
ductwork/ rough-in 6 1080, 1090, 1100 - ACAL 1ST
1150
1st floor Door &
Window
Frames
5 1090, 1100, 1280 SS - WINT 1ST
1090, 1100, 1280 FF -
1190 Roof trusses 8 1080, 1090, 1100 - ROSS Roof
1230 Roof Sheathing 5 1190 - ROSS Roof
1240 Roof felt 1 1230 - RABT Roof
1250 Building Dry-in * - 1240 - GC ALL
1260 Soffit & fascia 3 1250 - ROSS Roof
1265 Roof Shingles 6 1240 - RABT Roof
1270 Roof insulation 2 1250 - ROSS Roof
1280 Internal partition
framing
12 1250 - ROSS ALL
Activity
ID
Activity Title
Duration
(Days)
IPA
Rel.
Type
Lag
(Days)
RESP Area
6. 6
* NTP is a start milestone & Building Dry-in is a finish milestone.
1290
1st floor: hang
doors & windows 10 1150, 1280 - WINT 1ST
1300 1st floor drywall 8 1280 - WALL 1ST
1310 1st floor HVAC air
handler
5 1140, 1300 - ACAL 1ST
1320 1st floor suspended
ceiling
8 1300 - WALL 1ST
1330
1st floor plumbing:
install fixtures 2 1060, 1300 - PLMX 1ST
1340
1st floor paint/wall
covering 10 1320 SS 4 WALL 1ST
1330 - 1ST
1350 1st floor electrical
finish
6 1130, 1320 - ZAPP 1ST
1360 1st floor flooring 12 1340, 1350 - TACO 1ST
1440 HVAC: Install
equipment
1 1140, 1300, 1190 - ACAL ALL
1460 Stucco & Paint to
ext. walls
8 1260 - WALL ALL
1470 Site work 15 1020, 1090 - MART ALL
1480 Plumbing finish 2 1330, 1190, 1300 - PLMX ALL
1490
HVAC thermostat
& test
1
1350, 1080, 1090,
1100,
1280, 1300
- ACAL ALL
1500 Electrical final 4 1340, 1350 - ZAPP ALL
1510 Building clean-up 2
1265, 1290, 1360,
1460,
1480, 1490, 1500
- GC ALL
1520
Final check /
Occupancy
Certificate
1 1470, 1510 - GC ALL
10. 10
STEPS INVOLVED IN SCHEDULING
Creating EPS
To create an ideal schedule for any project, first step is to collect data available for the
project. The following steps can be followed in Primavera P6 software. Create the
complete structure of the company with its branches, which is executing the project
using primavera P6. This is known as Enterprise project structure (EPS).
Creating new project
The project constitutes a plan for creating a product or service contains a set of
different activities and associated information. The project is governed under
respective divisions in EPS. That can be given planned start and finish dates. Global,
resource or project calendar is assigned by the project.
11. 11
Work breakdown structure
WBS elements have defined and organize the project elements. It helps to clearly identify the
deliverables, report and summarize project schedule and estimated cost data at different levels of
detail. WBS is a hierarchy of any project work that must be accomplished to complete a construction
project. Each project has its own project WBS hierarchy structure with top level WBS element being
equal to that of each EPS node of the project. Each WBS element contains more detailed in WBS
levels, activities, or both resources constrain.
12. 12
Defining activity
It is the smallest subdivision of a project are the fundamental and key work elements of a project and form the top to lowest level of a WBS. The
characteristics Activity like ID, activity name, start and finish dates, activity calendar, activity codes, activity type, constraints, expenses,
predecessor and successor relationships, resources, roles etc.
13. 13
Relationship between activity
By assigning succeeding, preceding activities with significant relationship to the overall project activities, form a network, scheduling the
activities should be connected to each other.
Finish to start (FS) relationship
Start to start (SS) relationship
Finish to finish (FF) relationship
Start to finish (SF) relationship
14. 14
Creating a calendar
The calendar can create and assign it to each activity. These calendars define the available work hours in each calendar days. Also specify
national holidays, organizations, and project- specific work/non a workdays and resource vocation days.
15. 15
Activity Duration
When planning the work, the project duration is entered in the original duration field. The actual duration can only be entered for the project
activities, which are completed.
Activity Dates
The following types of project activity dates available in the primavera; actual start, planned start, actual finish, planned Finish.
16. 16
Creating baseline
A complete copy of the original schedule is a simple baseline plan which provides a target against
which a project’s performance is tracked. Choose project. Maintain baseline. Then add and save a
copy of current project as a new baseline B1. Then choose project
baseline as B1 and assign primary baseline as B1. Daily updates to be made. firstly, Start date and
end date Choose the activity to be updated. Then in the activity details window, select status tab.
Then tick mark started if the activity has been started and select the date. Tick mark finished if the
activity has been finished and select the finish date.
Scheduling:
A Primavera P6 schedule typically includes the following steps:
1. Planning stage – where a project statement is made describing the project, highlighting
all phases. Sub sections could include legal requirements, Quality Assurance etc.
2. The WBS lists the deliverables of the project.
3. Create Project Calendars for activities and resources. These can include the standard 5-
day workweek, shift patterns, etc.
4. Create activities for the project, breaking them down into manageable pieces of work
and assign resources.
5. Milestones – Activities spell out the steps to meet a Milestone. Milestones have a fixed
date but no duration and are a specific point in time during the project lifecycle. They
are used to measure progress towards completion. They may be included for budget
checks or as a reference point, which marks a major event or decision point within the
project.
6. Relationships are links between activities which create the sequence and network logic
for the project e.g. Activity B cannot start before Activity A has finished.
7. Assign Resources – Human resources such as a particular skill set, equipment,
facilities, other costs can be assigned to individual activities.
8. Risk – Capture the potential risks and dependencies, which could affect the delivery of
a milestone or deliverable.
9. Schedule baseline – A schedule baseline is approved by the project stakeholders and
incorporates the cost baseline (which is the approved budget) prior to the start of the
project.
10. Execution – Moving to the execution phase requires monitoring and controlling of the
project schedule. Regular updates from the work performed together with remaining
effort required are essential. Additional work scope or change orders will need to be
considered and may affect the schedule.
A Primavera P6 schedule’s primary purpose is to manage the amount of time, effort and cost it takes
to complete a project scope of work to its defined quality standards
17. 17
CONCLUSION
In this project, we named it "Office Building-01" and assigned it the ID "OB1." Which
has a total of 40 activities and a total duration of 94 days, with an early start date of
19-dec-21 and an early finish date of 26 march, there are 20 critical activities, and
delays in critical activities lead to delays in the project, there were two milestones,
with NTP being a start milestone and Building Dry-in being a finish milestone. The
total estimated cost of the entire project was $304,600.00.
QUESTIONNERE
A. What is the total duration in days? Report the project start and finish dates.
We have created a project for a one-story concrete office building with a floor
space of around 4,000 square feet (SF). A slab on grade (SOG) supports the
floor, which is supported by concrete columns and concrete masonry unit
(CMU) walls. Wood trusses support the roof, which is covered in sheathing and
asphalt shingles.
The project duration is 94 days and the project Start date is 19 - December -
2021 and the Project Finish date is 26-March-2022
18. 18
B. What is the budgeted total cost in Dollars?
The budgeted total cost in Dollars for the whole project is $304,600. Refer to fig 1 for the Detailed view of COST
LOADING CHART.
19. 19
C. Print out the WBS chart showing all levels. Use white color for the chart and the box backgrounds.
20. 20
D. Print out the activity network showing only the critical activities. Update the template to show activity ID,
original duration, early start and early finish for each activity. Use white color for the chart and the box
backgrounds. Do not group the activities and sort all ascendingly using the early start.
21. 21
E. Prepare a tabular report showing the activity ID, activity name, original
duration, early and late dates, and the total float. Activities to be sorted
ascendingly using the ID and grouped using WBS
22. 22
F. Prepare a tabular report showing only the activity ID, the activity name
and the budgeted total cost in Euro. Sort the activities in a descending
order from the highest to the lowest cost. Grouping is NOT required.
Report the exchange rate and show the total budgeted cost for the project
Activity ID Activity Name
Budgeted Total Cost
(In dollars $)
Conversion rate(dollar to euro)
Budgeted Total Cost
(In EUROS €)
OB1-1 Office Building-01” $304,600.00 0.90 274,140.00
€
OB1-1.1 General $0.00 0.90 -
€
A1010 Completionof Project $0.00 0.90 -
€
A1000 Commencement of Project $0.00 0.90 -
€
OB1-1.01 ALL $94,100.00 0.90 84,690.00
€
1470 Site work $30,000.00 0.90 27,000.00
€
1440 HVAC: Install equipment $22,000.00 0.90 19,800.00
€
1500 Electrical final $9,500.00 0.90 8,550.00
€
1460 Stucco & Paint to ext. walls $7,000.00 0.90 6,300.00
€
1040 Foundation $6,000.00 0.90 5,400.00
€
1490 HVAC thermostat &test $5,000.00 0.90 4,500.00
€
1480 Plumbing finish $4,500.00 0.90 4,050.00
€
1280 Internal partition framing $4,500.00 0.90 4,050.00
€
1010 Mobilization $3,000.00 0.90 2,700.00
€
1050 Fill,compact,and treat soil $2,000.00 0.90 1,800.00
€
1510 Building clean-up $600.00 0.90 540.00
€
1520 Final check / Occupancy Certificate $0.00 0.90 -
€
1250 Building Dry-in $0.00 0.90 -
€
1030 Excavation $0.00 0.90 -
€
1020 Clear & grub $0.00 0.90 -
€
1000 Notice to proceed (NTP) $0.00 0.90 -
€
OB1-1.02 1ST $179,700.00 0.90 161,730.00
€
1320 1st floor suspended ceiling $75,000.00 0.90 67,500.00
€
1350 1st floor electrical finish $16,000.00 0.90 14,400.00
€
1360 1st floor flooring $13,000.00 0.90 11,700.00
€
1090 1st floor external CMU walls $10,200.00 0.90 9,180.00
€
1100 1st floor internal CMU walls $9,500.00 0.90 8,550.00
€
1330 1st floor plumbing: install fixtures $8,800.00 0.90 7,920.00
€
1130 1st floor electrical rough-in $7,500.00 0.90 6,750.00
€
1140 1st floor HVAC ductwork $7,000.00 0.90 6,300.00
€
1300 1st floor drywall $6,500.00 0.90 5,850.00
€
1340 1st floor paint/wall covering $5,700.00 0.90 5,130.00
€
1290 1st floor: hang doors &windows $5,200.00 0.90 4,680.00
€
1310 1st floor HVAC air handler $4,000.00 0.90 3,600.00
€
1150 1st floor Door & Window Frames $3,500.00 0.90 3,150.00
€
1060 1st floor plumbing rough-in $3,500.00 0.90 3,150.00
€
1080 1st floor columns $2,300.00 0.90 2,070.00
€
1070 SOG $2,000.00 0.90 1,800.00
€
OB1-1.03 ROOF $30,800.00 0.90 27,720.00
€
1190 Roof trusses $10,000.00 0.90 9,000.00
€
1265 Roof Shingles $8,000.00 0.90 7,200.00
€
1270 Roof insulation $5,000.00 0.90 4,500.00
€
1260 Soffit & fascia $3,500.00 0.90 3,150.00
€
1230 Roof Sheathing $3,500.00 0.90 3,150.00
€
1240 Roof felt $800.00 0.90 720.00
€
23. 23
G. Prepare a tabular report listing the activities that start early during
January and February 2022 sorted ascendingly using the early start. Show
only the activity ID, activity name and the early start. Do NOT group the
activities.
24. 24
H. Print out a histogram showing the daily budgeted total cost in Dollars
25. 25
I. Print out a histogram showing the weekly total labor units.
26. 26
J. Print out a histogram showing the daily distribution of carpenters during January
27. 27
K. Assume that the original duration of activity 1360 is 16 days. What is the
project total duration and early finish date? Explain changes if any.
As this activity is not a critical activity, the total time of the project remains
unchanged at 94 days. As a result, we expect to complete the project by March
26th, 2022.
L. Assume that the original duration of activity 1310 is 10 days. What is the
project total duration and early finish date? Explain changes if any.
As this activity is not a critical activity, the total time of the project remains
unchanged at 94 days. As a result, we expect to complete the project by March
26th, 2022.
M. Suppose that there are only 4 working days during the week and the week
starts on Saturday. Report the project total duration and early finish date.
Discuss changes if any (do NOT consider the change in the previous
question).
With a 6-day work week, the project was scheduled to take 94 days to complete,
with an Early Finish date of March 26, 2022. The work week has been modified
to four days beginning on Saturday; the entire duration of the project will
remain the same at 94 days, but the early Finish date will be moved to April 13,
2022.
N.
1. Foundation activity mandatory finish on January 13, 2022. Check the
project duration, is there any change. Why?
There will be no change in project duration because the activity start date is 19
December 2021 and the activity is required to mandatory finish on 13 January
2022 without any constraints.
2. Site Work to start as late as possible. Check the project duration and the
start & finish dates of this activity, is there any change. Why?
The project duration (94 days) will not change because the activity's previous
Early start date is 10 February 22 and previous Early finish date is 26 February
2022. After assigning start as late as possible constraint to activity Site Work,
the Activity get impacted and will be shifted to a new Early start date of March
9, 2022 and New early finish date of March 24, 2022. As the activity is non
critical activity, so there is sufficient float available of 27 days, which leads to
the activity to be delayed by 27 days and it has no impact on total project
duration.
30. 30
Schedule Report
1. Scheduling/Leveling Report –
Default
Project..................................................
OB2
Projects:
OB2..................................................
Office Building-02”
2. Scheduling/Leveling Settings:
---------------------
3. General
Scheduling ......................................................
Yes
Leveling ........................................................
No
Ignore relationships to and from other projects .................
No
Make open-ended activities critical .............................
No
Use Expected Finish Dates .......................................
Yes
Schedule automatically when a change affects dates ..............
No
Level resources during scheduling ...............................
No
Recalculate assignment costs after scheduling ...................
No
When scheduling progressed activities use .......................
Retained Logic
Calculate start-to-start lag from ...............................
Early Start
Define critical activities as Total Float less than or equal to 0
Compute Total Float As ..........................................
Finish Float
31. 31
Calculate float based on finish date of .........................
Each project Calendar
Calendar for scheduling Relationship Lag ...........
Predecessor Activity Calendar
4. Advanced
Calculate multiple float paths...................................
No
5. Statistics:
Projects.......................................................
1
Activities.....................................................
40
Not Started....................................................
40
In Progress....................................................
0
Completed......................................................
0
Relationships..................................................
79
Activities with Constraint.....................................
1
PROJECT: OB2 ACTIVITY: 1040 FOUNDATION
6. Errors:
Warnings :
Activities without predecessors..................................
1
Project: OB2 Activity: A1000 Commencement of Project
Activities without successors....................................
1
PProject: OB2 Activity: A1010 Completion of Project
32. 32
Out-of-sequence activities.......................................
0
Activities with Actual Dates > Data Date.........................
0
Milestone Activities with invalid relationships..................
0
Finish milestone and predecessors have different calendars.......
0
7. Scheduling/Leveling Results:
Projects Scheduled/Leveled.....................................
1
Activities Scheduled/Leveled...................................
40
Relationships with other projects..............................
0
Data Date........................................................
19-Dec-21
Earliest Early Start Date........................................
19-Dec-21
Latest Early Finish Date.........................................
26-Mar-22
39. 39
COMPANY PRODUCTS
• Passenger Car Tires
• Light Truck Tires
• Truck and Bus Tires
• Tractor Front and Rear Tires & Tubes
TIRE:
A tire is a strong, flexible rubber casing attached to the rim of a wheel. Tires provide a
gripping surface for traction and serve as a cushion for the wheels of a moving vehicle.
Tires are found on automobiles, trucks, buses, aircraft landing gear, tractors and other farm
equipment, industrial vehicles such as forklifts, and common conveyances such as baby
carriages, shopping carts, wheel chairs, bicycles, and motorcycles.
Tires for most vehicles are pneumatic; air is held under pressure inside the tire. Until
recently, pneumatic tires had an inner tube to hold the air pressure, but now pneumatic tires
are designed to form a pressure seal with the rim of the wheel.
Components of Tire:
40. 40
• Inner liner
The inner liner is an extruded halo butyl rubber sheet compounded with additives that result
in low air permeability. The inner liner assures that the tire will hold high-pressure air
inside, without the air gradually diffusing through the rubber structure.
• Body ply
The body ply is a calendared sheet consisting of one layer of rubber, one layer of reinforcing
fabric, and a second layer of rubber. The earliest textile used was cotton; later materials
include rayon, nylon, polyester, and Kevlar. Passenger tires typically have one or two body
plies. Body plies give the tire structure strength. Truck tires, off-road tires, and aircraft tires
have progressively more plies. The fabric cords are highly flexible but relatively inelastic.
• Sidewall
Sidewalls are non-reinforced extruded profiles with additives to give the sides of the tire
good abrasion resistance and environmental resistance. Additives used in sidewall
compounds include antioxidants and antiozonants. Sidewall extrusions are nonsymmetrical
and provide a thick rubber area to enable molding of raised letters and sidewall
ornamentation.
• Beads
Beads are bands of high tensile-strength steel wire encased in a rubber compound. Bead
wire is coated with special alloys of bronze or brass. Coatings protect the steel from
corrosion. Copper in the alloy and sulfur in the rubber cross-link to produce copper sulfide,
which improves bonding of the bead to the rubber. Beads are inflexible and inelastic, and
provide the mechanical strength to fit the tire to the wheel. Bead rubber includes additives to
maximize strength and toughness.
• Filler
The filler is a triangular extruded profile that mates against the bead. The apex provides a
cushion between the rigid bead and the flexible inner liner and body ply assembly.
• Chafer
A key component of the tire that is the contact point between the tire and the wheel,
designed to withstand forces the wheel puts on the tire during mounting as well as the
dynamic forces of driving and braking.
41. 41
• Belt package
Belts are calendered sheets consisting of a layer of rubber, a layer of closely-spaced steel
cords, and a second layer of rubber. The steel cords are oriented radially in radial tire
construction, and at opposing angles in bias tire construction. Belts give the tire strength and
dent resistance while allowing it to remain flexible. Passenger tires are usually made with
two or three belts.
• Tread
The tread is a thick extruded profile that surrounds the tire carcass. Tread compounds
include additives to impart wear resistance and traction in addition to environmental
resistance. Tread compound development is an exercise in compromise, as hard compounds
have long wear characteristics but poor traction whereas soft compounds have good traction
but poor wear characteristics.
• Cushion gum
Many higher-performing tires include an extruded component between the belt package and
the tread to isolate the tread from mechanical wear from the steel belts.
TIRE PRODUCTION FLOW CHART:
42. 42
MATERIALS USED:
• Natural Rubber, or Polyisoprene is the basic elastomer used in tire making.
• Styrene-butadiene co-polymer (SBR) is a synthetic rubber which is often
substituted in part for natural rubber based on the comparative raw materials cost
• Polybutadiene is used in combination with other rubbers because of its low heat
build-up properties
• Halo butyl rubber is used for the tubeless inner liner compounds, because of its
low air permeability. The halogen atoms provide a bond with the carcass
compounds which are mainly natural rubber. Bromo butyl is superior to
Chornobyl, but is more expensive
• Carbon Black, forms a high percentage of the rubber compound. This gives
reinforcement and abrasion resistance.
• Silica, used together with carbon black in high performance tires, as a low heat
build-up reinforcement.
• Sulphur cross-links the rubber molecules in the vulcanization process .
• Accelerators are complex organic compounds which speed up the vulcanization
Activators assist the vulcanization. The main one is zinc oxide.
• Antioxidants and antiozonants prevent sidewall cracking, due to the action of
sunlight and ozone.
• Textile fabric reinforces the carcass of the tire. Steel for making steel belts.
HOW A TIRE IS MADE:
Tire manufacturing is a complex technical process. It can be broken down into eight
manufacturing stages:
• Mixing
Various grades of natural and synthetic rubber are blended in an internal mixer
(commonly known as a Banbury) and mixed with carbon black and other chemical
products. This blend is called the "master batch" and its make-up is carefully
constructed according to the desired performance parameters of the tire.
• Calendaring
Textile fabric or steel cord is coated with a film of rubber on both sides. Calendared
textiles such as rayon, nylon and polyester are used for the casing and the cap plies.
Steel cord is used for the belts.
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• Tread and Sidewall Extrusion
The tread and sidewalls are constructed by forming two different and specifically
designed compounds into tread profiles by feeding the rubber through an extruder.
Extruders produce continuous lengths of tread rubber, which are then cooled and cut,
to specific lengths.
• Bead Construction
The bead core is constructed by coating plated steel wires, which are wound on a
bead former by a given number of turns to provide a specific diameter and strength
for a particular tire.
• Tire Building
Tire building is traditionally a two-stage process. In the first stage, the inner liner,
the body plies and the sidewalls are placed on a building drum. The beads are then
positioned, the ply edges are turned around the bead core and the sidewalls are
simultaneously moved into position. In the second tire building stage, the tire is
shaped by inflation with two belts, a cap ply and the tread being added. At the end of
this stage the tire is now known as a "green tire".
• Curing
The green tire is now placed in a mold inside a curing press and cured for a specific
length of time at a specific pressure and temperature. The finished tire is then ejected
from the mold.
• Trimming -
Excess rubber is removed from the cured tire on a trimming machine.
• Inspection -
Before the tire is allowed to go to the dispatch warehouse, it is inspected both
visually and electronically for quality and uniformity.
RAW MATERIAL WAREHOUSE:
R.M.W.H receives, holds and releases material for operations and production. The main
responsibility of the R.M.W.H is to keep control of inventory so that there is no material
shortage. As rubber is main raw material required to make a tire and is currently imported,
R.M.W.H has to order it at least 90 days before the stock runs out.
It is divided into three sections:
1. Hardware Section:
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It is responsible for providing tools and machine spare parts required for the
maintenance of machine.
2. Raw material Section:
Its responsibility is to issue raw material. Production Planning and Control prepares
a RMR (Raw material requisition) and sends it to R.M.W.H by AS-400 system.
R.M.W.H verifies the availability of raw material and dispatches the material.
3. Scrap Section
The purpose of scrap section is to ensure the sale/disposal of factory process scrap
material, obsolete spare parts and fixed assets.
MIXING:
The two major ingredients in a rubber compound are the rubber itself and the filler,
combined in such a way as to achieve different objectives.
In general, there are four major rubbers used: natural rubber, styrene-butadiene rubber
(SBR), polybutadiene rubber (BR), and butyl rubber (along with halogenated butyl rubber).
The first three are primarily used as tread and sidewall compounds, while butyl rubber and
halogenated butyl rubber are primarily used for the inner liner, or the inside portion that
holds the compressed air inside the tire.
Fillers such as carbon black and silica are used. Other ingredients also come into play to aid
in the processing of the tire or to function as anti-oxidants, anti-ozonates, and anti-aging
agents. In addition, the "cure package”—a combination of curatives(sulfur) and
accelerators—is used to form the tire and give it its elasticity.
After the compound is determined, the mixing operation takes place. The mixing operation
is a batch operation, with each batch producing about 200 kilograms of rubber compound in
less than three to five minutes. The mixer is a sophisticated piece of heavy equipment with a
mixing chamber that has rotors inside. Its main function is to break down the rubber bale,
fillers, and chemicals and mix them with other ingredients.
The sequence in which the ingredients are added is critical, as is the mixing temperature,
which can rise as high as 160 - 170 degrees Celsius. If the temperature is too high, the
compound can be damaged, so the mixing operation is typically accomplished in two stages.
The curative package is added in the final stage of mixing, and the final mixing temperature
cannot exceed 100-110 degrees Celsius, or scorching (premature curing) may occur.
Once the mixing is completed, the batch is dumped out of the mixer and sent through a
series of machines to form it into a continuous sheet called a "slab.” The slab is then
transferred to other areas for bead wire assembly preparation, inner liner calendaring, steel
and/or fabric belt/ply cord calendaring, tire sidewall extrusion, and tire tread extrusion.
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MACHINES AVAILABLE IN MIXING DEPARTMENT:
1. F-270 Banbury (PLC based) – For Master Batch
2. HF-270 Banbury (PLC Based) – For Finish Batch
3. KN-01 Kneader – For Master Batch
4. KN-01 Kneader – For Master Batch
DUAL EXTRUDER:
Its purpose is to form tread (component of tire which encounters the road surface) and
sidewall (bridges between tread and bead) of truck, tractor and passenger Bias tires.
Dual extruder is hot feed which is why it requires two mills to warm and soften the
compound fed.
MAIN PARTS OF DUAL EXTRUDER:
1. Breakdown Mill
2. Feed Mill
3. Hopper
4. Screws
5. Die
In the initial stage, carefully identified slabs are transported to breakdown mills. These mills
feed the rubber between massive pairs of rollers, over and over, feeding, mixing and
blending to prepare the different compounds for the feed mills where they are slit into strips
and then carried by conveyor belts to the hoppers/feed areas. There are 4 breakdown mills in
total. There are two large screws in a sealed housing run by a single motor. Line speed and
rpm of screws is set by panel. Both the screws push the compounds towards a single die
having the cavity of the size of tread or sidewall to be extruded. Cushion gum if required is
applied separately after extrusion from the die. The extruded component is then sent to the
cooling line. Next it goes to the automatic running cutter which cuts according to the size set
ROLL CALENDER:
A machine for calendaring the fabric with rubber sheets on both sides. The machine consists
of four large diameter rollers for the operation. The fabrics come in huge rolls, and they are
as specialized and critical as the rubber blends. Many kinds of fabrics are used: polyester,
rayon or nylon. Most of passenger tires have polyester cord bodies. 4 roll calendar produces
calendared sheet with fabric inside known as ply which is used in both radial and bias tires.
First, a pre-set number of fabric cords under proper tension are continuously pressed
through two steel rollers, and rubber compound is added to the opening area between the
rollers. Then the rubber compound is pressed into, on top of and on the bottom of the fabric
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or steel cords. A continuous sheet of cord-rubber composite goes through several more
rollers to ensure good penetration and bonding between the rubber and cords. Quality is
measured by the thickness of the sheet, spacing between cords, the number of cords and the
penetration of rubber into the composite sheet. The composite sheet is then cut into
appropriate sizes, shapes, and angles depending on the desired contour of the tire.
Four mills of large diameter prepare rubber feed for the calendar.
1. CM 3 - Breakdown mill
2. CM 4 - Warm up mill
3. CM 5 - Feeding mill
4. CM 6 - Blending mill or Holding mill
Units/Components of 4 Roll Calendar:
1. Let Off unit 1 and 2
2. Splicing unit
3. Tensiometro Unit
4. Precalendaring unit
5. Banana roll
6. Trimming unit
7. 4 rolls or Z calendar
8. Perforator
9. EPI (Ends per inch)
10. Cooling drums
11. Accumulator
12. Winding Unit 1 and 2
13. Storage Area
TRIPLEX:
Its purpose is to form tread and sidewall of radial tires.
There are three screws of diameter 90mm, 200mm and 150mm in a sealed housing having
individual feed area. Housing is fitted with small pins to blend the rubber properly. Multiple
dies can be installed at the same time. Cushion gum can be applied separately if required.
Cooling is provided so that the rubber shrinks before it is cut into size.
Triple extruder is cold feed thus there is no requirement for mills to warm up the feed as in
the case of dual extruder. A cutter which runs according to the instructions fed in the PLC is
provided at the end of the shrinkage conveyor for cutting the sidewalls and treads into sizes.
Treads and sidewalls are weighed in terms of weight per unit length. Line speed of the
shrinkage conveyor is adjustable and the variation in line speed is automatically induced in
the rpm of the screws so as to compensate if material shortage occurs at die. Cement is
applied to the treads and sidewalls which have been cut. Cement improves the adhesion of
the rubber.
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Three metal sensors are installed at the individual feed area so that no metal can get inside
the housing of the screws and cause damage to them.
STOCK PREPARTION AND BEAD/BAND BUILDING:
The bead component of the tire is a non-extensible composite loop that anchors the body
plies and locks the tire onto the wheel assembly so that it will not slip or rock the rim. The
tire bead component includes the copper coated steel wire loop, apex or bead filler; the
chafer, which protects the wire bead components; the chipper, which protects the lower
sidewall; and the flipper, which helps hold the bead in place. The bead wire loop is made
from a continuous steel wire covered by rubber and wound around with several continuous
loops. The precision of the bead circumference is critical. If too small, tire mounting can be
a problem; but if too loose, the tire can come off the rim too easily under loading and
cornering conditions. The bead filler is made from a very hard rubber compound, which is
extruded so as to form a wedge. Filler and bead are joined manually in a rotating disc.
There are two machines which are used to make beads
1. BD-2 - produces one bead at a time.
2. BD-3 –produces three beads at a time.
Spools of steel wires are place over pulleys which can rotate on the application of tensile
force on the wires. A machine pulls all the wires at the same time from the coils and an
extruder coats rubber on the wires. Next the rubber coated wires are shaped into circular
bands which are then cut. There are various disc sizes for different tires.
Machines which are used in stock preparation:
1. FC-2
2. FC-3
3. FC-4
4. FS-1
5. FS-2
Band is a set of plies utilized in tire building. Plies are cut according to the circumferential
size of tire and at an angle. The plies are built at opposite angles forming crisscross pattern.
Band is built according to the ply rating of the tire. It is distinguished by two types
• Tractor
• Truck/Bus
Band Building sections of five machines:
BB-1, BB-2, BB-3, BB-4, BB-5
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These machines consist of two rollers which press multiple plies together with help of
pneumatic pressure.
There are three types of bands made:
1. First band - 4 plies, breaker and drum squeegee assembly.
2. Second band - Only plies
3. Third band – 2 plies and 2 breakers
STEELASTIC AREA:
This section produces steel belts which are used in Radial tire building.
High tensile brass coated steel cords (multi strand) are used in the construction of tire belts.
The brass coating is done to make rubber adhere to the steel.
The storage of these brass coated steel cords is in a temperature and humidity controlled
environment (the creel room). The temperature is kept around 27 degrees Celsius and
humidity around 30%. Otherwise, corrosion due to moisture may cause the steel belts to lose
adhesion with rubber. The steel wire passes from the creel room on rollers through aligning
combs into the calendar where the wires are coated with a thin sheet of skim stock rubber.
A pre – set number of steel cords under proper tension are continually pressed through two
steel rollers, and simultaneously the rubber compound is added to the opening area between
the rollers. A thin layer of rubber is applied into, on top of and the bottom of the fabric. A
continuous sheet of cord – rubber composite goes through many more subsequent rollers to
ensure proper penetration of rubber between the cords and desired adhesion between rubber
and the fabric. Cooling drums cool down the strip and later Columbia Cutter cuts the belts at
required angle and length. Winder assembly winds the belts which then go into storage area
where temperature is controlled.
49. 49
RADIAL TIRE BUILDING:
It is a type of construction of tire in which ply cords extending from beads are at right angle
to the centerline of tread and parallel to each other. A radial tire is built on a flat drum in a
two-stage process. In the first stage, the inner liner is wrapped around a drum and the body
ply is wrapped on top. The bead assemblies are then positioned, and a bladder on the drum
is inflated and pushed in from both ends of the drum, forcing the body ply to turn up to
cover the bead assemblies. The sidewall sections then are pressed onto both sides. At this
stage assembly is called carcass.
In the second stage of the tire building process, another machine is used to apply the steel
belts in crisscross pattern, nylon cap ply, and tread on top of the first stage. At this stage
assembly is called a green tire.
The main components of first stage machine (PB-11, PB-13 to PB-19) are:
• Drum
• Bead applier
• Turn up assembly
The main components of second stage machine (PR-1 to PR-5) are:
• Belt and tread drum
• Transfer ring
• Expander
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BIAS TIRE BUILDING:
A type of construction of tire in which ply cords extending from bead to bead are at angle
lying between 30 to 40 degrees. Successive plies at opposing angles are laid over each other
to form a crisscross pattern to which the tread is applied. Green tires of bias construction are
assembled in a single stage thus only one machine is required for complete assembly of tire.
There are currently six tire building machines for Bias construction.
The main components of bias tire building machine are:
• Drum
• Bead applicator
• Back tool assembly
The following components are assembled:
• Drum squeegee
• Bands & Beads
• Sidewall
• Chafer
• Breakers
• Tread
Number of bands and breakers to be used are dependent on the type of tire manufactured i.e.
truck/bus, tractor.
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RADIAL VERSUS BIAS PERFORMANCE:
TUBE SECTION:
Tubes :
A single extruder makes green tubes which are then spliced to join the edges. A valve is
fitted to the tube for inflation purposes. Lastly, they are cured. Butyl rubber is used in
making of tubes. Finally they are inspected for any leakage of air.
Curing Machines:
TP-1 to TP-10 for passenger car tire tubes
TP-10 to TP-15 for truck and tractor tire
tubes
Bladder :
The Bladder is flexible rubber that is filled with steam or hot water when tire is being cured.
The bladder is attached to the inside of the mold. A single bladder lasts for about 200 curing
cycles. It also forms marks/impressions on the inside of attire. The stock for bladder comes
from single extruder. The dimensions and geometry of the tire to be cured determine the
bladder to be chosen for the job.
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Flaps :
It is used at the interface of the tire. It protects tube from the rim.
Machines:
FL-01 for trucks and tractors
FL-02 for passenger cars
CURING:
Curing is the process of applying pressure to the green tire in a mold in order to give it its
final shape, and applying heat energy to stimulate the chemical reaction between the rubber
and other materials. In this process the green tire is automatically transferred onto the lower
mold bead seat, a rubber bladder is inserted into the green tire, and the mold closes while the
bladder inflates. As the mold closes and is locked the bladder pressure increases so as to
make the green tire flow into the mold, taking on the tread pattern and sidewall lettering
engraved into the mold. The bladder is filled with a recirculating heat transfer medium, such
as steam, hot water, or inert gas. At the end of cure the pressure is bled down, the mold
opened, and the tire stripped out of the mold.
Types of Presses:
1. Dome Type
2. Platen Type
Dome type presses are used for tractor and truck/bus tires. Whereas Platen type presses are
used for light truck tires and all radial tires.
Procedure for DOME:-
1. 200 psi steam in bladder, orifice open.
2. 200 psi steam in bladder, orifice close
3. DOME steam , 145 C
4. Delay cure for cool mold (>20 minutes)
5. Non-circ hot water in bladder
6. Circ cold water thru bladder
7. Full blow down open
8. Drain dome steam
9. Full blow down
10. Apply 200 psi steam flush in bladder
11. Apply vacuum in bladder
12. Open mold and remove tire
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FINAL FINISH:
Tire inspection is the last step in the tire manufacturing process. The tire inspection
includes:
• Trimming of the mold flash and micro-vents
• Visual inspection for appearance and to spot obvious defects
• X-ray examination to check internal structure and to spot defects
• Tire durability, uniformity, and weight balance inspection
After curing is complete, the tire is removed from the mold for cooling and then testing.
Each tire is thoroughly inspected for flaws such as bubbles or voids in the rubber of the
tread, sidewall, and interior of the tire. Then, the tire is placed on a test wheel, inflated, and
spun. Sensors in the test wheel measure the balance of the tire and determine if the tire runs
in a straight line. Bulge test is also done by mounting the tire on the rim and inflating the
tire with an air pressure of 50psi. If any penetration of air is found in the tire, it is rejected.
FINISHED GOODS WAREHOUSE:
The products that fulfill all the quality parameters are sent to F.G.W.H for shipment to the
dealers and OEMs. Tire packaging is also done here. They also collect the claimed tires.
A warehouse sheet is generated in the holding area when the tires are been handed over to
F.G.W.H. The sheet is verified and signed by warehouse supervisor before the tires are let in
the warehouse.
A locking key system is used which means when tires are in the holding area, the warehouse
gate is locked and similarly when tires are in the F.G.W.H, the gate to holding area is
locked.
A Sales Invoice is generated in the sales department when tires are to be dispatched from
F.G.W.H. In case of transfer of tires to branch offices, a Transfer Invoice is generated.
F.G.W.H verifies the invoices and plans the logistics.
PRODUCTION PLANNING AND CONTROL:
Production Planning and Control organizes and coordinates the entire range of
manufacturing activities. It provides the overall plan to which people and departments must
work. It ensures that material, tools, equipment, personnel and documentation are in the
right place at the right time. It continually monitors and updates the plans and schedules to
meet machine breakdowns and other manufacturing hazards.
54. 54
Functions Of PPC:
1. Demand Planning
Input: Annual Forecast, Production History, Specifications, Machine Utilization,
Product Profitability, Quality key indicator, Plant shutdown.
Source(s): Marketing, PPC, Technical, Finance, I.E, Q.A, P.E
Output: Machine and tool requirement, Production profitability, Annual production
forecast.
Period: 2-3 Years
Frequency: Annual or when required
2. Master Production Schedules
Input: Raw material, Special Orders, F.G Inventories, 3 month sales forecast, Trial
Runs request, Preventive maintenance schedule, Machine manning.
Source(s): Marketing, FGWH, RMWH, Technical, P.E, Production
Output: Monthly Production Forecast.
Period: Three Months
Frequency: Monthly
3. Material Requirement Planning
Input: Monthly Production Forecast, Raw material inventories / On Order, Order
rules / Lead time, Specifications.
Source(s): PPC, Technical, Supply
Output: Raw material explosion, Raw material status.
Period: Three Months
Frequency: Monthly
4. Capacity Requirement Planning
55. 55
Input: Machines capacity / Efficiencies, Machine Utilization.
Source(s): PPC, Industrial Engg
Output: Machine Utilization.
Period: One Month
5. Daily Schedules
Input: Urgent need, Updating of specifications, Updating of Standards, R.M/F.G
/W.I.P inventories, Machines availability, Material rejection.
Source(s): Marketing, PPC, Technical, RMWH, FGWH, I.E, Q.A, P.E
Output: Shop Floor Schedule.
Period: Daily
Daily Schedules
Input: Material rejection, FIFO usage, Material order status, Inventory status, Shop
floor schedule, Stock W/A advise, Leftover stock.
Source(s): Production, PPC, Technical, RMWH, FGWH, Q.A, Supply
Output: Inventories control, Production report.
Period: Daily
6. Process Priority
Input: Daily Production report, Machine breakdown, Bottle necks, R.M/F.G
/W.I.P movement, O.E shipment status.
Source(s): Production, PPC, Technical, P.E, FGWH
Output: Production analysis, Problem Solving.
Period: Daily
56. 56
QUALITY ASSURANCE:
Quality Assurance department ensures that ISO standards are followed and is responsible
for its certification. Its main purpose is preventing the claims from customers. In case of
receiving such claims on quality of provided products and services, the department starts
searching the reasons and effects of the revealed discrepancies. If a tire on examination is
found to be having some manufacturing defect, the Company will either repair it free of cost
or make reasonable allowance on pro-rata basis on the purchase of a new tire. This
allowance will be based on the actual wear and balance left of a tire. It is also responsible
for taking market surveys to check if the product is meeting its requirement.
The department also carries out investigations in case of recurring problems.
TYRE ENGINEERING:
Tire engineering department provides the technical specifications for the manufacture of the
tire e.g. mold design etc. They develop drawings, specifications and do mold inspection in
case of new vendors.
Molds:
The mold in the curing press is the cavity in which tire is cooked and given the final shape.
The mold has the embossed imprints of the tread pattern and codes printed on the sidewall
of the tire. The two basic type of molds used are:
1. Segmented mold
These molds are divided into segments in the circumferential projection of the tire.
The number of segments can be 6 or more depending on the size of the tire. The
engravements of sidewall are on a separate part.
2. Two parts mold
These molds are divided into two parts along the centerline of tread. The
engravements are on both parts of the mold.
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Tire Markings:
MAINTENANCE PLANNING/MECHANICAL
MAINTENANCE:
Maintenance planning department determines the scope for the maintenance activities. They
generate a work plan for maintenance activities and monitor efficiency of maintenance.
They plan and schedule activities. They prepare preventive maintenance work order and
prepare work completion against work order sheets. They fill/update machine history using
AS-400. Maintenance activities are planned in case of mechanical failure, electrical failure
and preventive maintenance. AS-400 software is used to look for machine history while
generating work plan. They are also responsible for maintaining maintenance inventory and
work side by side with R.M.W.H. The reorder point ("ROP") is the level of inventory when
an order should be made with suppliers to bring the inventory up by the Economic order
58. 58
quantity ("EOQ"). Economic order quantity is the level of inventory that minimizes total
inventory holding costs and ordering costs.
There are three types of maintenance:
1. Preventive Maintenance:
Maintenance carried out before any hazard/breakdown occurs. For preventive
maintenance, history of a machine is prepared and studied according to which a
yearly plan for maintenance is prepared upon which maintenance is carried out.
2. Predictive Maintenance:
Maintenance which is carried out on prediction of technician. A technician is
assigned to the machine whose work is to troubleshoot any smaller problems and if
he finds any sign which indicates the possibility of a big problem occurring, he
raises a work order to maintenance planning department.
3. Corrective Maintenance
Corrective maintenance can be defined as a maintenance task performed to identify,
isolate, and rectify a fault so that the failed equipment, machine, or system can be
restored to an operational condition within the tolerances or limits established for
in-service operations.
QUALITY CONTROL:
Quality Control Department has following responsibilities and sections.
1. X-Ray testing.
2. Material Testing Lab
3. Reliability Test
i) Endurance Testing
ii) High Speed Testing
4. Plunger test.
5. Tire Uniformity machine – used to check if forces are balanced.
6. Statistical Process Control e.g. control charts etc.
7. In Process Inspection.
8. Final Inspection
Quality control begins with the delivery of raw materials. Company chemists do
random testing of the raw materials in the material testing lab. Throughout the batch
mixing operation, samples of the rubber are drawn and tested to confirm if the rubber
fulfills its requirement. A variety of nondestructive evaluation techniques are also used
such as X-ray videography, reliability testing, and plunger testing for cured tires.
