The two case studies show how TireSight transforms tire detection data into real operational value – helping sites identify critical tire risks earlier, take action before issues escalate and improve planning and decision-making across the fleet.
Case Study One: The advantages of detecting and acting on hazardous tires sooner
TireSight detections deliver the most value when they are followed by timely action when potentially serious issues are flagged.
Tracking the time from detection to tire removal helps demonstrate how autonomous detection insights improve safety and fleet productivity.
Sending trucks back into production with detected tire defects has been shown to cause greater tire damage severity further down the line.
Using real data, we can see how quickly tires are removed after a TireSight inspection triggers a work order.
Insights from TireSight
TireSight inspection data was analyzed across multiple sites to measure the elapsed time between the first detection of potential or ongoing issues and the subsequent tire removal.
The results are expressed as cumulative percentages of tires removed following detection.
The graph on the left shows the following removal timings (hover over data for more information).
Key Outcomes
The measured time between TireSight detection and tire removal defines how long a tire observed by TireSight as damaged tire remains in operation.
- 73% of detected tires removed within 2 days
- Over 80% removed within the first week
- All tires with detected issues were ultimately removed, showing the effectiveness of TireSight’s detection capabilities
Shorter removal times provide clear operational advantages by reducing the duration of exposure to known tire-related risk scenarios. The outcomes below summarize the overall advantages associated with early tire removal after TireSight has flagged an issue.
Case Study Two - Avoiding worst-case downtime scenarios through early front tire intervention
Front tire failures in the pit result in significant equipment downtime and production loss.
When a front-position tire fails during operation, recovery and repair can take many hours, directly impacting equipment availability and productivity.
A tire running flat on a haul truck in operation creates extended downtime and productivity loss.
A front-position tire failure on a large haul truck (T-118) resulted in 12 hours of downtime. This event is used as a benchmark to represent a worst-case front tire failure scenario.
The Solution
KalPRO TireSight was implemented on the site to detect front-position tire risks early while trucks were still in production, enabling quick tire changes to reduce damage where required. This approach replaces the risk of an unplanned failure with a planned tire change following an alert.
To establish a fair comparison, only front-position tire events flagged by TireSight were evaluated, and each event was compared against this same worst-case benchmark.
The Results
Early intervention of detected issues using TireSight enabled trucks to be recalled for immediate tire changes across the 17 detections.
If TireSight had not been installed and trucks experienced the same failure while working in the pit, the total downtime loss would have equalled $244,800 and production loss $3,060,000.
TireSight minimized these potential losses by 72%, ensuring productivity and truck uptime were maintained.