BRISA Bridgestone Scales for Continental Business Excellence and Boosts Manufacturing-Process-Query Speed by 100x
 
 

BRISA Bridgestone Scales for Continental Business Excellence and Boosts Manufacturing-Process-Query Speed by 100x

The roots of BRISA Bridgestone Tire Manufacturing and Trading were laid by the Sabancı Group, the leading industrial conglomerate in Turkey, as a 100% Turkish investment named Lassa Tire Manufacturing and Trading Inc. Production started in 1977, with sales in 60 Turkish provinces through 186 authorized dealers. In response to growth in the global tire industry, the Sabancı Group signed a joint venture agreement with Bridgestone Corporation of Japan, a world-leading tire manufacturer—with each party holding an equal share in the company. Today, BRISA Bridgestone is a leading tire manufacturer in Turkey and Europe’s seventh-largest tire manufacturer, internationally recognized for customer satisfaction and business excellence.

 
 

 
 

Challenges

A word from BRISA Bridgestone Sabancı Lastik San. Ve Tic. A.Ş.

  • “We decided to reallocate our production platform from HP to Oracle Exadata after a few proof of concept tests that demonstrated Oracle to be the only provider capable of supporting our around-the-clock production of 10 million tires per year. After the deployment, we achieved 10x better data compression, 100x faster query speed on manufacturing processes, 30% lower licensing costs, and a dramatic decrease in system downtime.” – Mustafa Tacettin, Plant Automation Systems Manager, BRISA Bridgestone Sabancı Lastik San. Ve Tic. A.Ş.

  • Eliminate system crashes and performance issues—due to the use of concurrent databases for online transaction processes and online analytical processes when consolidating machinery production data into data warehouses and analyzing the data—to avoid production downtime and loss of revenue
  • Enable efficient and accurate plant automation intelligence, some of which was impossible to achieve on the legacy HP platform—for examples: intelligence regarding scrap monitoring and waste management
  • Enable system engineers to monitor production-critical parameters in real time—such as the ingredients of mixed rubber compounds and production-room temperature—and tune those parameters to prevent faults and defects in the final product
  • Increase data warehouse capacity with extreme data compression to decrease total cost of ownership without sacrificing system performance and availability

Solutions

Oracle Product and Services

  • Deployed Oracle Exadata Database Machine—engineered to be the highest performance and most available platform for running the Oracle Database—to support plant automation processes by feeding key parameters from nearly 600 production lines into the data warehouse
  • Enabled engineers to obtain in real time the analytical data needed for production tuning by increasing system query speed more than 100x
  • Gained the ability to immediately adjust production parameters and obtain the internationally recognized tire quality that keeps drivers safe on any road and ensures top-class racing performance in global motorsport competitions
  • Increased the availability of production-critical applications from 99.6% to 99.9%—decreasing downtime from 36 hours to 7 hours per year and enabling BRISA to produce more tires—because Oracle Exadata provides redundant hardware that is engineered to protect against disk, server, and network failures
  • Achieved a tenfold reduction in production database storage requirements with Oracle Exadata’s advanced Hybrid Columnar Compression capabilities, speeding query performance, thanks to improved disk scan rates and making 30 TB of uncompressed data fit into a data storage of just 2.5 TB
  • Postponed the need for new storage investment until 2020, thanks to the deployment of Oracle Exadata High Capacity disks—allowing BRISA to reallocate the budget to other business development needs, such as improving market edge and customer satisfaction
  • Gained the ability to implement production planning and quality assurance reporting, reducing central processing unit (CPU) usage from 40% to 8% by utilizing a unique technology that offloads data-intensive search query language operations into the Oracle Exadata Storage Servers—greatly accelerating query execution and eliminating bottlenecks
  • Enabled the company to increase backup system budgets and provide full protection against primary database failures and site disasters without incurring higher total cost of ownership by decreasing the number of licensed CPUs from 16 to 12

Why Oracle

“We have been using Oracle technology since 2000. Oracle Exadata Database Machine enabled us to make tire manufacturing more efficient and implement critical reports that we did not have the capacity to generate before. Working with the same manufacturer for both software and hardware provides multiple advantages: software compatibility, platform scalability and reliability, a single point of contact for all support and technical maintenance needs, and eased planning for business development,” said Mustafa Tacettin, plant automation systems manager, BRISA Bridgestone Sabancı Lastik San. Ve Tic. A.Ş.

Implementation Process

“Oracle partner Bimsa created a test environment on Exadata with actual data from BRISA Bridgestone. We ordered Oracle Exadata after completing a few proof of concept tests. The system was up and running in a few days and the deployment caused no business interruption. We are planning to take our Tire Description System—our proprietary software that enables us to create and bring to market more than 1,300 different tires—from the current UNIX-based platform to Oracle Exadata. In the process, we will most likely migrate our current SAP-based enterprise resource planning application as well,” Tacettin said.

Partner

“We worked with Oracle partner Bimsa before. It helped us deploy most of our pre-Exadata Oracle footprint, such as Oracle Database, Oracle Business Intelligence, and Oracle SOA Suite. Bimsa’s expertise and flawless implementations allowed us to experience the full benefits of Oracle products for more than a decade and gave our management the confidence they needed to approve a migration from HP to Oracle Exadata for all our plant automation systems,” Tacettin said.