TBR Machine

Business challenge

Truck and bus radial tyre building is unforgiving of control drift: the machine coordinates multiple axes against a build recipe where small positional errors compound into scrap. Sumitomo's Ladysmith plant needed the machine's control system brought to a state where it could be maintained locally, on plant that had accumulated undocumented modifications over its service life.

Engineering approach

Ivevane began by reverse-engineering what was actually installed rather than trusting the drawings. Once the system was documented, the control and motion architecture was rationalised onto a supported platform, with the build sequence expressed so that plant engineers could read and adjust it without specialist support.

Implementation

Control panels were built and tested in the Boksburg workshop, tagged per circuit and despatched to Ladysmith for installation during a planned maintenance window. Commissioning covered loop checks, axis calibration and sequence proving, followed by handover training for the plant's maintenance team.

Outcome

The machine returned to service on a documented, supportable control platform, with the plant's own maintenance team able to diagnose and adjust it rather than escalating every fault to an external integrator.

Business benefits

• Undocumented plant made maintainable again
• Control platform brought onto supported hardware
• Plant maintenance team able to self-serve on routine faults
• Complete as-built documentation delivered at handover

Future expansion

With the machine documented, further build recipes and additional tyre specifications can be introduced as configuration rather than as a control system project.