MRF Tyres Digital Intelligence Implementation Case Study

This case study outlines MRF Tyres' implementation of digital intelligence to address persistent machine breakdowns and unplanned downtime in its tire manufacturing processes. The initiative began in May 2024 at the Arakkonam plant, where the company deployed 40 sensors on the 4 Roll Calendar to enable continuous monitoring and prescriptive recommendations. The pilot's success led to a rapid scale-up, increasing the number of sensors to over 6,000 across 16 plants by the end of 2025. The case study details the transformation from reactive to predictive maintenance, resulting in significant production outcomes, including the elimination of 1,833 hours of unplanned downtime and achieving a mean time between failure (MTBF) of 2,091 hours across critical assets. Additionally, it highlights the implementation of 374 prescriptions with a 95.73% implementation rate, demonstrating the effectiveness of prescriptive AI in enhancing reliability and operational efficiency in high-volume tire manufacturing.