Tyre management: the $1,000 decision made by the person with the least information

Tyre management: the $1,000 decision made by the person with the least information

Tyres are the second or third largest variable cost in most fleet operations.

They are also, consistently, the least systematically managed.

The reason is structural: tyre purchase decisions are typically made at the point of failure — by a driver on the road, or by a workshop technician who needs to get the vehicle back in service. Neither person has visibility of the fleet’s tyre procurement history, the current contract pricing, or the total cost of ownership implications of the brand and spec being selected.

A study published in the Fleet Management Weekly industry database documented that, on fleets without a tyre management policy, the average price variance for identical tyre specifications purchased across a 12-month period was 34%. The same tyre, bought under different circumstances, costs 34% more or less depending on where, when, and by whom it was purchased.

On a 50-vehicle fleet spending $120,000 per year on tyres, that variance represents $40,800 in avoidable overspend — simply from buying the same product at inconsistent prices.

The documented cost drivers

• Inflation pressure. The US Department of Energy documents that tyres underinflated by 10 PSI increase rolling resistance and fuel consumption by approximately 1%. On a heavy truck tyre correctly inflated to 110 PSI, a 10% underinflation means 11 PSI under — measurable on a weekly walk-around. Across a 20-truck fleet, consistent 10% underinflation costs approximately $18,000–$24,000 per year in excess fuel.
• Rotation and alignment. The Tyre Industry Association documents that proper rotation extends tyre life by 20–30%. Wheel misalignment — measurable with a $200 alignment check — can reduce tyre life by up to 45% on the affected axle. An alignment check that costs $50 and extends a $400 tyre’s life by 45% has a documented ROI of 260%.
• Retreading. On heavy trucks, retreaded tyres meeting international quality standards (ECE Regulation 108/109 or equivalent) perform comparably to new tyres on drive and trailer axles at 40–60% of the new tyre cost. Fleet operators in South Africa and East Africa with formalised retreading programmes document savings of $800–$1,400 per truck per year. The practice is underutilised in West Africa relative to its documented performance record.

A tyre management policy does not require software

It requires:

1. An approved supplier list with negotiated rates.
2. A weekly walk-around checklist that includes tyre pressure per axle.
3. A tyre record card per vehicle showing fitment date, position, brand, and tread depth at each service.
4. A retreading assessment at each removal rather than automatic replacement.

The people buying your tyres are making $1,000 decisions with incomplete information. Give them a policy.

Sources

US Department of Energy Fuel Economy Data; Tyre Industry Association performance research; Fleet Management Weekly tyre procurement variance study (2023); ECE Regulation 108/109 retreading standards.