The reliable spine
The non-AI spine is the source-linked workflow: clean records, rules, calculations, integrations, exception queues, approvals and reporting for Scrap, mill loss, mis-cure and yield, by recipe and what you actually make.
Rubber & Tyres
Scrap, mill loss, mis-cure and yield, by recipe and what you actually make
The floor knows waste is high; nobody can say which recipe, press, mould or shift drives it, because it lives in a paper batch and reject register that never gets costed, and the mill loss, regrind and scrap-sale value never reconcile. The compound recipe both sets the part's behaviour and hides its cost, so an over-loaded filler or an off-cure quietly bleeds margin batch after batch. A retreader's whole business is other people's casings. Each comes in from a fleet or own stock, passes inspection, buffing, building, curing and finishing, then goes back, and today it is tracked on a paper inward-register that does not reconcile to dispatch. Casings get lost or swapped, a fleet's casing is returned to the wrong owner, scrapped casings are not accounted, and job-work billing goes unchecked. The same gap hits crumb and pyrolysis units tracking scrap-tyre tonnage in and recovered output out. The schedule lives on a whiteboard or in one planner's head; OEM and mining schedules arrive by email and WhatsApp; at-risk jobs and cure-press bottlenecks are discovered late, causing missed dispatches and, for OEM components, line-stop penalties.
Who has it
All segments, with different drivers: green-tyre and cured reject and tread or casing yield for tyre and tube manufacturers; cavity reject, flash and mis-cure by mould for moulded and extruded component makers, who also send parts out for plating or bonding; tread-rubber scrap, cure rejects and recovery yield for retreaders and rubber-processing units, including crumb, reclaim and pyrolysis units; and build, ply-up and cure scrap for conveyor belt, hose and seal makers. The casing and job-work register matters most for retreaders and rubber-processing units; the schedule-versus-capacity warning matters most for moulded and extruded component makers and for conveyor belt, hose and seal makers, where OEM and project schedules and penalties are tight, and also for tyre and tube manufacturers.
What we build
Digitise the batch and waste capture at the banbury, mill, mould and press, cluster it by recipe, job, machine, shift and customer, and reconcile a true scrap-mill-loss-and-regrind ledger so the missing kilograms and the scrap-sale value finally show up against the batch that caused them. No model changes a recipe or a cure setting; it shows where the waste is. A casing and job-work register that captures each casing or scrap-tyre lot inward (owner, size, condition), tracks its stage and the tread or process applied, and reconciles return and scrap to the inward record and the job-work bill, so nothing is lost, swapped or billed wrong, and the EPR tonnage falls out of the same record. A read-only layer over the order book, customer schedules and press/line availability that flags schedule-versus-capacity conflicts and at-risk jobs days earlier. The planner decides; the layer only warns.
What is automated, where AI helps, who signs off
Automation for the routine. A person on every decision that matters.
Where AI helps
AI is limited to bounded reading, extraction, matching, clustering or drafting from the firm's own data for Scrap, mill loss, mis-cure and yield, by recipe and what you actually make; it never owns the number, the approval, the promise or the decision.
Who signs off
A named person signs off anything touching money, stock, a customer promise, a regulated filing, a payment, a price, a credit decision or a people decision.
What changes day to day
The few recipes, presses and repeat jobs driving most loss surface quickly. Illustrative: a tyre maker cut cured-tyre rejects by about a quarter by fixing the worst-offending compounds and presses. Every casing is accounted from inward to return; lost and swapped casings stop, job-work bills get checked, and the EPR tonnage is a by-product of the record instead of a year-end scramble, so casing losses and unbilled job-work fall. At-risk jobs surface days earlier; fewer missed dispatches and penalties, so penalty events on key accounts fall.
Illustrative outcome
The few recipes, presses and repeat jobs driving most loss surface quickly. Illustrative: a tyre maker cut cured-tyre rejects by about a quarter by fixing the worst-offending compounds and presses. Every casing is accounted from inward to return; lost and swapped casings stop, job-work bills get checked, and the EPR tonnage is a by-product of the record instead of a year-end scramble, so casing losses and unbilled job-work fall. At-risk jobs surface days earlier; fewer missed dispatches and penalties, so penalty events on key accounts fall. Illustrative; final numbers come from your own data.
Illustrative; final numbers come from your own data.
Path to the build
How this one gets built.
Book a free 60-minute call, then a free Blueprint on the firm's own records. Deep-dive and build, followed by run and govern so the workflow keeps paying back.
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What tends to pair with this one.
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