This thesis aims to analyse how and with which tools it is possible to measure and reduce the cost of complexity in a tyre manufacturing plant. Given the intricate structure of tyres, increasing product customization and abrupt changes in market demand add more complexity to already complex manufacturing processes. In the first section of this paper, all the critical parts of a truck tyre and production procedures are summarized. In the next section, the components of manufacturing costs are listed, and the cost of complexity is defined. Then all the major factors affecting the cost of complexity are analysed one by one.