BUSINESS PROCESS RE - ENGINEERING

Case Study

BHARAT FORGE

BHARAT FORGE

Bharat Forge is the world's largest forging company. Bharat Forge Limited (BFL), the flagship company of the USD 2.4 billion Kalyani Group, manufactures various forged and machined components for the automotive and non-automotive sector. Among the largest and technologically most advanced manufacturer of Forged & Machined components.

As one of Indias emerging multinationals, the company has manufacturing operations across 11 locations and 5 countries - 4 in India, 3 in Germany, one each in Sweden, USA & 2 in China and one each in Sweden & USA.
Backed by a full service supply capability and dual-shore manufacturing model, Bharat Forge provides end-to-end solutions from product conceptualization to designing and finally manufacturing, testing and validation.

FORGING
Forging is the shaping of metal using localized compressive forces. Forging is often classified according to the temperature at which it is performed: '"cold," "warm," or "hot" forging. Forged parts can range in weight from less than a kilogram to 580 metric tons Forged parts usually require further processing to achieve a finished part.

OBJECTIVES
Reducing

the downtime of the the cycle time of the activity. the productivity of the

production.
Reducing

Thus,increasing

process.

MAJOR REASONS

Operation:

Set Up Mismatch Corrections Heat Symbol Change

Dies:

Die Cooling Job sticking to the die. Strategic die grinding. Trimmer broken Trimmer opening

SOLUTIONS

Instant cooling methods. Die lubrication. Coating Layer of non conductor material Introduction of Robots Pressurized die cleaning. SMED ( Single Minute Exchange Of Die ) Training to the employees. Pokayoke by making the operational procedure standard.

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