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The economic software solution for the modern retreading of commercial vehicle tyres
Modern tyre retreading companies are becoming
more and more a part of international acting
service organisations dealing with the tyre
management of fleet vehicles. This has resulted
in high expectations such as a high product
quality while the price pressure is constantly
increasing, a quickest possible delivery time and
the capability to react in a flexible way. Facing
all that and at the same time securing and incre-
asing market shares requires integrated system
solutions!
Clearly focusing on the requirements of the tyre
retreading industry, fa/r offers a high-perfor-
mance solution which:
Offers a practice-oriented representation and
support of the company-specific production
processes
Is highly accepted by its users
Is very user-friendly
Is fast to implement
Is easily integrated into an existing system.
�
What you gain with fa/rRecognise the sign of the times and optimise your processes by utilising fa/r!
Our long-term experience in the field of soft-
ware for the tyre retreading industry and the
consideration of our customers’ requirements
and experiences guarantee the suitability of our
retreading program in practice. Decreased administrative costs, even
with increasing production, due to total
process monitoring and process control
Process optimisation based on real long-
term data
Productivity increase due to automation
Trouble-free interchange of staff
members during the production process
and reduced error risk due to machine
interfaces and defined rules
Reduced production costs due to efficient
deployment of staff and material
Optimised material stock due to integra-
tion in supply chain systems
Shorter processing times, high product
quality and a transparent production
process increase customer confidence
and strengthen existing customer
relations
Automated data exchange with tyre trade
programs prevents media breaks and
multiple data capturing
Increased quality awareness of the
staff due to detailed production
documentation
Individual reports and statistics enable
detailed evaluations
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Seamless integration of production, warehouse and office
fa/r controls and documents the production of
retreaded commercial vehicle tyres, in both cold
and hot retreading processes, from the reception
of the casings up to the delivery of the finished
tyre. Based on memorised process data, fa/r
enables the regular optimisation of processes
within the retreading factory.
The seamless integration of all relevant company
domains firstly ensures the availability of all
process information, and secondly enables
centralised process monitoring and control.
fa/r functions:
Planning and control of production
orders in pre cure and mould cure retrea-
ding processes
Dynamic data management, situation-
related data disposition and capturing
Automated control of modern processing
machines
Complete production documentation
Logistics support due to mobile data
capturing
Material disposition with integration in
supply chain systems
Extensive statistic evaluations and
reports
Electronic data exchange with tyre trade
systems
fa/r functions in administration,
production and warehouse
pre cure and mould cure retreading processes
grinding
tread cutting
building
autoclave
final inspection
delivery labels
casingreceipt
initialinspection
warehouse labels
buffing
repairing
building
measuring
presses
office warehouse
data exchangetyre trade
fa/r application and database
service
LAN, WAN, internet
casing account
casings,treads, finished tyre
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Flexibility and Scaleability due to Modularity
Due to its modularity and scaleability in connec-
tion with extensive adaptive features, fa/r can
be adjusted to different user environments and
grow with changing requirements. After setting
up a start configuration the system can, accor-
ding to the needs, be extended in its depth (new
stations) or in its functions (new modules). Many
data interfaces assure the communication with
existing IT applications (tyre trade), ERP systems
of material suppliers and processing machines
and lines.
Computer-aided production
control for the tyre retreading
industry with the modular
fa/r system
The characteristics of fa/r are:
Perfected functionality
Useful modularity
High scaleability
Fast implementation
statistics
casing account
software interfaces
(ERP)
process data recorder
fa/r production
fa/r basic
machine interfaces
complaints
handheld
warehouse
fleet management
interface
supply chain interface
presses data
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fa/r basic
Basic ModuleSecured data basis, clear rules, flexibility due to parameterisation
The fa/r basic module contains the central data
for the entire system. Extensive functions assure
the adaptation of the system to the operative
processes of the retreading factory.
Basic data administration (clients,
suppliers, tyres, treads, text blocks,
staff, process codes…)
Parameterisation, settings
Rules, plausibility checks
Rights administration
Order control, delivery
Items on stock
Order department
Production documentation
fa/r Basic Module
Plausibility checks, established user rights and
clear rules guarantee an economic utilisation of
the solution.
�
pre cure and mould cure retreading processes
grinding
tread cutting
building
autoclave
final inspection
delivery labels
casingreceipt
initialinspection
warehouse labels
buffing
repairing
building
measuring
presses
pre cure mould cure
fa/r production
Production ControlFar-sighted and on the right track
Production planning
Allocation and gathering of relevant data
at the production stations
Automated data exchange with machines
and lines
Integrated rules for defined reactions to
special situations
- Tyre resetting
- Casing failure or quality degrading
- Change of treads
- Change of moulds
Automated material administration
Foreman function for monitoring and
control
Production control, which is the heart of the
solution, receives information in real time from
the production process in order to provide the
production manager at all times with an exact
process overview and hence allow for fast and
Computer-aided production control in pre cure and
mould cure retreading processes with fa/r
secure planning and control. The production
manager is supported by rules which are adjusted
to the user‘s requirements and saved within the
system.
�
Additional ModulesCompleted functionality!
Additional modules complete the fa/r basic func-
tionality and allow for the configuration of a
client system according to the real requirements
of the tyre retreading factory.
With requirements changing, all additional
modules can be retrofitted and used. This enables
the fa/r installation to grow with the require-
ments of the retreading company.
Automated data exchange with programs from the areas tyre trade and financial accounting
Client and order data are transferred to fa/r from the tyre trade
fa/r sends order-relevant production data back for invoicing
Consistent master data
Seamless integration, without media break, fast, faultless
software interfaces
(EPR)
Preconfigured evaluations, based on
memorised production data
Variable selection criteria
statistics
Mobile station for special areas such as
EM retreading, heat presses, warehouse
areas
Online or batch processing
handheld
�
Fast and flexible handling of clients‘
casings and retreading orders
Organised according to make, dimension,
category
Cyclic account balancing
casing account
Exact complaint processing with auto-
matic access to all production data
Location of credit notes and technical
data
Examination of weakest points based on
real process data
complaints
Capturing of the presses data (heating
time, mould and bellows change, heated
tyres) by aid of a handheld and transfer
to the production database
presses data
Inventory maintenance for casings,
treads and produced tyres (warehouse,
storage place)
warehouse
Modularity brings sustainability:
The continuous development of new
additional modules, mostly based on our
users‘ ideas, mirrors the growing
functionality of fa/r.
10
Machine InterfacesConsistent Automation!
The trend towards industrial tyre retreading
comes along with an increased use of automatic
machines and lines in the production process. In
order to fully use this potential fa/r offers data
interfaces, which minimise and facilitate easy
manual operations, exclude data input faults,
increase the rate of machine utilisation and take
over process data.
machine interfaces
ShearographyCompletion of the tyre documentation by
adding test pictures and results
Marangoni SFERA
SDS ITT
Bandag ��00 INSIGHT
BuffersAutomated transfer of the retexturing
program and back transfer of retexturing
and process data (buffed circumference,
buffed width, process time)
Bandag ��10E, ��10E
Collmann RM��
Matteuzzi RAS�0-DC�
Marangoni BlueDart
Builders
Automated transfer of the building program
and the casing and profile data
Bandag �10�E, �10�E
Bridgestone baz �1�0
Autoclave recorder
Completion of the tyre documentation by
vulcanisation data (pressure, temperature,
time)
Ellerbrock, Bandag EPC
Current automation interfaces*
* Further machines and lines can be integrated if required. Pre-
set: Shearography (Steinbichler, t.r.m.) • buffers
(Marangoni, SIO, t.r.m.) • builders (Matteuzzi, A-Z, t.r.m.)
• autoclave units (t.r.m.)
11
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Module Process Data RecorderWith fa/r always up to date and on the right track!
process data recorder
The integrated process data recorder in fa/r
provides the data basis for process analyses
directly from the production process.
Real process data provide the basis for
process analyses and show optimisation
potential
Productivity evaluations
Product hit list
Efficiency evaluation of automated
machines
Evaluation of cycle times, turnaround
times of tyres and orders
Evaluations of “problem tyres”
Recognition and evaluation of seasonal
stock movements
Recognition of weakest points and deve-
lopment of reserves
Rate of machine utilisation
- Total running time
- Productivity progression
- Utilisation frequency of given programs
- Set-up time compared to working time of
automated machines
Personnel statistics
- Staff-related
- Between shifts
- Between factories
Product-specific process data
Work time per tyre
Lehmann Mertens Bauer
Example for collected process data
Station Rauher
1�
Supply Chain Interface The rolling warehouse!
Modern industrial order and supply systems
feature automated and custom-made order
processes and just-in-time deliveries. The supply
chain interface allows for the integration of
retreading companies in supply chain manage-
ment systems of material suppliers.
supply chain interface
Reduced bound capital for the mate-
rial warehouse of the retreading factory
(rolling warehouse)
Automatic ordering considering order
need, warehouse and disposition stock
Adaptation of discount steps
Automatic update of material
master data
- Integration of new profiles
- Order ban on profiles being phased out
- Production ban on profiles
Electronic delivery note in order to
facilitate material reception
Transfer of manufacturer‘s information
on profiles
delivery material update
ERP system of the supplier
order
Integration of the fa/r system in individual order and
delivery systems
1�
Computer-aided Tyre Retreading User Benefit
As an organisation and control tool within the
retreading factory, fa/r considerably increases
the work efficiency at all company levels, from
the managing director over the works manager
down to the production, administrative and
warehouse staff!
Productivity increase Increase of the rate of automation of
modern machines due to machine
interfaces
Online information
Fast and faultless identification of
casings and retreaded products
Electronic data exchange with traders
and suppliers
Cost-cutting Reduced administrative effort
Reduced warehousing costs due to dispo-
sition and order-controlled integration
into supply chain-systems
Optimised line and staff deployment
Avoiding cost drivers
Quality Assurance Improved quality awareness of the staff
due to detailed documentation
Defined rules and plausibility checks
decrease failure risks
Machine interfaces ensure quality
standards
Better customer satisfaction Shortened delivery times due to
reduction of cycle times and optimal
material disposition
Improving product quality means less
complaints
Auto-information system for traders
Exact treatment of scrapped casings and
complaint management
1�
Improved flexibility Order planning based on customers‘
orders and warehouse production with
regard to material and dispo stocks
Facilitated handling due to utilising the
casing account
Machine interfaces reduce staff require-
ments and support the trouble-free
interchange of staff
Automatic documentation Support of quality assurance systems
as well as ISO �00� and ECE 10�
certification
Proof of all production information at
integrated stations
Extensive evaluations and reports in
order to measure and prove experiences
Process optimisation Real process data provide the data basis
for valuable productivity evaluations on:
- Staff
- Shifts and factories
- Products
- Machines
- Material flow
and enable a continuous process
optimisation
Computer-aided Tyre Retreading User Benefit
1�
Modern Software Solutions for the Tyre Market
Modern vehicle fleets require an impeccable
tyre management in order to maintain their
hold on the market. All partners participating
in the product “tyre retreading“, from mate-
rial suppliers to machine manufacturers to tyre
retreading factories to service points, are faced
with high requirements.
Our modern and practice-proven software solu-
tions support market participants of all levels in
efficiently organising their business processes,
from the material delivery in supply chain
systems to the control of the retreading process,
to the optimisation of the machine park mainte-
nance to the complete fleet management.
Production control of retreaded commercial vehicle tyres
Central maintenance management and optimisation of machines and lines
Modern management of commercial vehicle fleets including tyre manage-ment
Contact
PC-Soft GmbH
Adolf-Hennecke-Str. ��
D-01��� Senftenberg
fon +�� (�� ��) �0 ��-0
fax +�� (�� ��) �0 ��-1�
email [email protected]
web www.pcsoft.de
Sales Office Rhein-Main
Kurt-Blaum-Platz �
D-����0 Hanau
fon +�� (�1 �1) �0 �0 1-0
fax +�� (�1 �1) �0 �0 1-��