Goodyear Impact Manufacturing Technology

Goodyear’s revolutionary manufacturing technology, called IMPACT, stands for Integrated Manufacturing, Precision-Assembled, Cellular Technology.

In order to fully appreciate the IMPACT of this new technology, here’s a quick – and very simple – review of conventional tire manufacturing today:

First, natural and synthetic rubber, chemicals, carbon black, antioxidants and dozens of other ingredients are combined in giant mixing machines called Banburys.
The resulting compounds are combined with other materials and made into body plies, belts, beads and other components.

These pieces and parts are delivered from various locations throughout the plant to the tire builder, who literally assembles what is called a “green tire,” which is then cured in a press.
Combining these components and streamlining the delivery system are an integral part of IMPACT manufacturing technology.

IMPACT means:
Integrated Manufacturing – a systems approach to blending people productivity with innovative technology to produce higher quality tires.

Precision Assembled means that all materials in the finished tire are located exactly as specified by the design engineer.

IMPACT Cellular Technology minimizes transportation time and in-process inventory. This results in a shorter production cycle time.

“IMPACT integrates today’s highly efficient manufacturing systems with new precision technology for component formation, pre-assembly, automated tire assembly and curing, all within a cellular system,” according to Lowell Dunckel, Goodyear senior vice president for global product supply.
IMPACT optimizes quality, productivity and cost.

It is 43 percent more precise than the current industry capability. This improves ride, handling and treadwear.
It reduces tire weight and rolling resistance and improves tire appearance.
IMPACT optimizes the precision of tire components by employing technologies not previously used by the tire industry, forming and assembling components simultaneously.

It eliminates splices in critical tire components, cutting process steps in half and improving quality.
As to productivity, Dunckel said, the cellular process reduces cycle times by 70 percent.
It provides quality feedback, and is expandable in modular increments.
It increases productivity by 135 percent.

“With IMPACT, we can be much more flexible in manufacturing,” Dunckel said. “We can produce multiple sizes and types of tires simultaneously, make fast, automatic tire code changes and use more flexible tire constructions and designs. IMPACT reduces direct labor by 35 percent.”

“We can quickly integrate IMPACT technology into our facilities worldwide,” Dunckel said.

“This means that we don’t have to invest time and money building new plants or gutting
old ones.”

Reducing manufacturing costs is a key objective of any manufacturer, and Goodyear is no exception. “We are already the industry’s lowest-cost producer,” Dunckel said. “IMPACT takes us several steps further in reducing the costs of materials, manufacturing and investment.”
Following are seven major areas of cost reduction delivered by IMPACT:

• Material costs are reduced 15 percent.
• Labor costs are reduced 35 percent
• Energy costs are lowered significantly
• In-process inventory is cut in half
• Curing time is cut 20 percent
• Initial investment and floorspace are significantly reduced

IMPACT’s cellular technology can be easily and economically utilized in space much smaller than needed for conventional tire manufacturing.

“With IMPACT, we can site plants wherever they are needed – close to OE manufacturers or close to major consumer populations. IMPACT gives Goodyear several clear advantages over its competitors -- advantages in precision manufacturing; better uniformity and appearance; enhanced tire construction capability; fewer work minutes per tire, lower investment and lower overall tire cost,” Dunckel said.