How Apollo Tyres Uses AI-Driven APC for First Time Right Tyre Extrusion

This article describes how Apollo Tyres developed an AI-driven Advanced Process Control (APC) closed-loop system to eliminate startup instability in tyre extrusion manufacturing.

• AI model predicts optimal extrusion line speed at recipe changes using 200+ process features
• Real-time closed-loop controller monitors tread and sidewall profiles and automatically adjusts line speed
• Reduced startup rework by 26% and stabilization time by 40%, recovering ~20 production hours monthly
• Built on Amazon SageMaker for MLOps and Amazon Bedrock for agentic AI with AWS IoT Greengrass edge execution
• Integrated within TQM and Daily Work Management frameworks using I5 Agile and OPDCA methodologies
• Roadmap includes reinforcement learning, AI-powered SPC monitoring, and multi-line deployment

Apollo Tyres transformed manual extrusion startup into an autonomous AI system that achieves First Time Right production while augmenting operator expertise through structured governance and cloud-native architecture.