Brownfield Tire Plant Auditing - From Raw Material to Finished Product
With over a decade of hands-on experience designing and improving tire factories worldwide, our experts understand every process, machine, and challenge, because we’ve been there ourselves. We specialize in brownfield auditing and modernization, not general consulting, delivering practical, measurable results.
We work side by side with you to turn insights into real improvements, whether your goal is to increase output, speed up curing, cut waste, or increase automation. Every audit concludes with a phased, risk-free roadmap aligned with your production goals and budget, ensuring upgrades are implemented smoothly, safely, and without unnecessary downtime.
- Assess current production performance and detect bottlenecks
- Evaluate automation readiness and modernization potential
- Determine the current capability from a tire technological point of view and what is needed to improve to answer future requirements
- Identify opportunities for measurable cost and cycle-time reductions
- Create a clear roadmap for continuous improvement
OUR APPROACH
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Why Us
Real Factory Experience +
At Black Donuts, we combine deep technical know-how with real factory experience. Our in-house team of tire designers, material scientists, layout specialists, and automation engineers ensures every recommendation is grounded in practical, hands-on expertise, not theory.
Immediate Improvements +
We deliver immediate value through short-term process optimizations that can often be implemented right away, with little or no additional investment.
Data driven auditing +
Our smart data auditing approach goes beyond manual inspections. Using Digital Twin, MES Ontire®, and simulation data analysis, we detect inefficiencies and bottlenecks that are otherwise invisible, turning data into clear, actionable insights.
Sustainability expertise +
With strong sustainability expertise through InTire Labs, we integrate bio-based and recycled material insights into every audit, helping manufacturers align with evolving ESG requirements.
Turnkey execution +
We don’t just advise, we execute. Our turnkey approach ensures that identified improvements are transformed into upgraded factory capabilities, safely and efficiently.
End-to-end performance improvement +
From data to decisions, and from decisions to results
What We Offer vs Traditional Auditing
| Traditional Consulting | Black Donuts Advantage | |
|---|---|---|
| Industry focus | Broad industrial mix | 100% Tire manufacturing |
| Audit depth | Strategic overview | Full process & machine-level analysis |
| Execution | Advisory only | Audit + implementation |
| Tools | Standard data analysis | Ontire® MES, Digital Twin, FEA |
| Sustainability | Generic ESG templates | Verified with InTire Labs data |
| Cost & time | Long cycles, high fees | Modular, fast, result-based |
| Follow-up | One-time report | Continuous performance tracking |
Auditing Process
1. Audit Preparation
2. On-Site Audit
Our experts conduct floor walks, staff interviews, machinery inspections,
and process flow observations to get a full picture of current operations. We assess:
- Production areas, utilities, material flow, and bottlenecks.
- Machinery specifications, maintenance logs, and factory layout.
- Energy use and process efficiency figures.
- Product platforms, tire constructions, component libraries.
- Staff assessment, structure, and skill alignment.
3. Independent Data Analysis & Identification
We analyze collected data to identify bottlenecks, quantify losses, and benchmark your performance against best-in-class standards.
- Detect bottlenecks, safety or compliance risks, outdated equipment, and quality issues.
- Assess sustainability performance (emissions, waste, recycling opportunities).
4. Recommendations
We propose prioritized improvement actions and a clear assessment of upgrade options, risks, and ROI:
- Evaluate the technical and financial feasibility of potential upgrades.
- Identify risks of downtime, integration issues, and hidden costs.
- Prioritize quick wins vs. long-term strategic improvements.
5. Reporting, Upgrade Scenarios & Presentation
You receive a detailed report including before-and-after performance metrics. We present:
- Modular and phased solutions tailored to your needs and budget.
- Present scenarios with investment estimates, ROI, and implementation roadmaps.
- Engage in Q&A to address client concerns and refine options.
6. Roadmap & Implementation Plan
We deliver a step-by-step, phased implementation plan designed to minimize or eliminate production downtime.
Our plan aligns with your internal teams and external suppliers, ensuring smooth execution.
7. Ongoing Support & Monitoring
We stay involved after implementation by tracking KPIs, providing technical guidance during execution,
validating improvements, and offering continuous support for further optimization.
Contact us to schedule your audit and discover how we can help your factory reach its full potential.
