Slide 1

ABOUT BHARAT FORGE

Bharat Forgeis aforgingcompany based inPune, India. Bharat Forge Ltd. (BFL) is a subsidiary of the Kalyani group which was founded by Nilkanthrao Kalyani. Currently the chairman of the company is B.N. Kalyani, son of Dr. N Kalyani. Bharat Forge came into existence in year 1961. Forging began in 1967. The forging was carried out through hammer forging. In 1991, first Forging Modernization Division (FMD I) was established.The total cost for setting up the division was about 150 crores. The world's largest forging company with manufacturing facilities spread across India, United States, Germany ,China and Sweden, Bharat Forge manufactures a wide range of high performance, critical & safety components for the automotive & non-automotive sector. It is India's largest manufacturer and exporter of automotive components and leading chassis component manufacturer in the world. BFL's customer base includes virtually every global automotive backed by several decades of experience in component manufacturing & metallurgy, the company is now looking beyond automotive and has embarked on an ambitious and exciting journey to redefine its already existing presence across several critical business verticals such as oil & gas, power, locomotive & marine, aerospace, metals & mining, construction and general engineering

In Bharat Forge Ltd. products are produced both by

Closed Die Forging processOpen Die Forging process

Generally closed die forging process is used to produce automobile components like Crankshafts, Connecting Rods, and Axle Beam etc. While open die forging is used for producing components of various sectors like Marine, Defence, Aerospace, and Oil &Gas.

Bharat Forge Ltd (BFL) Mundhwa plant is divided into following major departments:

Sales/ITD (International Trade Dept.)Profit Planning Control (PPC)Material Dept.FinanceHuman Resource (HR)/ IRSafetyClosed die forging division (CDFD) Engg.Die ShopForge Shop (FMD I/II/III, HFD I/II)Heat TreatmentMachine Control Division I/IIMTBMetallurgical Quality Control Security

Closed Die Forging Division Engg:

In order to produce a customers product, it first has to be designed virtually. This task comes under CDFD Engg. which makes use of many designing and simulating softwares to estimate, design and optimize a given specimen.The process starts with estimation of force and energy required for the job by using Ansys which is determined by the 2-D or 3-D drawings given by the customer. Then it is sent to the design team which designs the tooling and die required for the job with the help of AutoCAD. Once the die is designed, it is sent to CAD department for its 2-D drawings to be generated which is carried out with the help of softwares like Unigraphics, Catia and ProE. Afterwards, a 3-D simulation software (Forge or Deform) gives necessary data about the thermal, defect, stress and energy distribution in the forging. Finally, the drawing and model are sent to the CAM department which writes the program for the CNC machines to produce the required die. Finally the drawing is optimized using various software.

Die Shop

Once the CDFD Engg. has issued the programs for CNC machines, the dies are manufactured in the die shop. The general process outlook is as follows. Firstly planning of the die to be manufactured for the given product is made i.e. the amount of time required for the manufacturing of the die prior to product manufacturing. . Finally dies are manufactured as per the required specifications in High Speed Milling Machines (HSM). After this if there is any wear or irregularities are there in the dies, then it is removed either through welding (in case of smaller dies) or CNC machines (for bigger dies). Finally surface finishing of the dies are made through Electron Discharge Machine (EDM) followed by Benching (i.e. polishing of the die). Then the die is checked in CMM and LMM machine for any defect present in the die after final finishing of the die.

Heat Treatment

After press forging, the products are quenched and thus, develop brittleness or sometimes, a customer has a special demand of heat treatment of the product. Whatever the case maybe, all the heat treatments are carried out by this department. Various processes available are annealing, normalizing, hardening, nitriding (exclusively for dies), carbo-nitriding, iso-annealing and carbon restoration. Annealing is process by which any residual stress due to thermal or mechanical loading is relieved by heating.Carbo-nitriding is the process by which case hardening is achieved for gears and other products.The shop has both batch-type and continuous-type furnaces. Various quenching media are used which include water, oil, polymer and even air.

Forge Modernization Division I (FMD I)

This department came into existence in 1991. It is a press forge and houses 5 presses namely,PTS 900 (16500 MT): It is a mechanical press and is the largest in BFL.PSH 4.560 (4560 MT): It is a screw press and uses a large flywheel for energy transfer.LKM 400 (4000 MT)LKM 2.500 (2500 MT)LMZ 2500 (2500 MT) The general process of the division is as follows:First billets are cut into suitable sizes and heated in an oil-fired surface to a temperature of 1280 degrees Celsius. The heated billets are de-scaled with water jets at high pressure. Then they are put into dies and pressed till they take the shape completely.

Forge Modernization Division II

This shop also follows the same process of forging as that of the FMD I/III. Firstly raw material as per the given specification of the product are sorted and cut in a band saw to the required dimensions. Then similar to FMD I here also the cut billet is heated in the oil furnace where 72 billets are heated simultaneously. After this the same procedure as that of FMD I/III is followed of that of upsetting, trimming and padding. FMD II shop contains screw presses of different capacity

16000 ton 6000 ton5000 ton2500 ton

Forge Modernization Division IIIThis division of Bharat Forge Ltd. comes under closed die Forge division. Generally in this division the process used for forging is similar to that of FMD I/II. This shop contains three screw presses, which are of following capacity12500 metric ton 8000 metric ton5500 metric tonIn this division firstly the raw materials in the forms of billets are cut into the required dimensions as per the customers specifications for the product. Then after this jobs were heated simultaneously in the oil furnace for a temperature range of 1230-1300 Celsius. Then we pass the heated job through rolling machine in order to increase its length and reduces the cross sectional area. After that job is sent to main press where firstly job is placed in the blocker die followed by finishing die in order to give the required shape. Then it is sent to trimming press where the flash produced during the forging is cut out. After this job is moved to padding press where it is straightened i.e. any bending that is present in it is removed. Finally finishing is performed using short blasting or short peening.

Heavy Forge Division I/II

This division comes under open die forging. These two shop is generally used to produce products of critical shapes , which cannot be produced by the closed die forging method. The products which are usually produced in this shop are wind mill shafts, gear blanks, mining manifolds, camshafts etc.HFD I shop contains a hydraulic press of 1600 Ton capacity (ZDAS).The shop also contains QKK12T manipulator having carrying capacity of 12 Ton and travel speed of 20-40 m/min. Similarily HFD II contains hydraulic press of 4000 metric ton aswell as manipulator similar to that of HFD I. The shop also contains various types of furnaces likeSlow cooling furnaceNormalizing furnaceTempering furnace

Forge Shop

This the oldest forging shop in Bharat Forge which uses Manual forging technique unlike FMD I/II/III which uses automatic forging machines. This shop contains Hammer Machine that is used for the forging of the job. Generally it is used to produce heavy or complex shape products, which cannot be manufactured, by FMD I/II/III shop.This shop can forge the given job both vertically as well as horizontally unlike FMD in which only vertical forging is done.Hammer used for forging in this shop is around 25000 pound.Hence it is not used for mass production but only for the production of the complex shapes.

Machined Components Division (MCD I)

MCD I is responsible for the grinding and finishing of the crankshafts that come out of the pressing shops. This shop has 11 lines for crankshaft finishing and 6 lines for non-crankshaft products (such as FAB assembly, knuckle, reinforcement brackets and Al forgings). All the output of this shop is for domestic sales only.The processes carried out on each line are roughly thesame which include milling of crank pin and journal, grinding of pin, journal, flange and thrust collar, cutting of key-slot, drilling of centre holes and super-finishing of the pin and journal to an average roughness of 0.07m. Finally it is checked for the correct dimension using different types of gauges.

Machined Components Division II(MCD II)

This department was set up in 2004 and is fully automated. It has 4 production lines and produces fully-finished crankshafts exclusively for export.The gantry system is fully automatic which reduces production time and lot rejection, even with 24 machines per line.The process sequence is similar to that of MCD I which includes grinding of flange, pin, journal, thrust collar, super-finishing of pin and journal, cutting of keyways, drilling of end-holes. The division produces 800 jobs per day. Tac time is 6.88 minutes per job.

Metallurgical Quality Control DivisionMQC division is responsible for the control of material quality that is used in the forging, both for dies and forgings. It houses apparatus for Jominy end-quench test, Kinematic viscosity test, Universal tensile test machine, Hardness machine etc. It carries out various tests on materials to find out the different physical and chemical properties of raw materials which are different grades of steels. Physical properties are also determined through microstructures which are seen through high magnification microscopes. Chemical properties are determined from the composition of the forging material.

Machine Tool Building (MTB)

MTB is a research and development department which caters to the needs of the other departments. Its main objectives are to procure machinery for BFL, re-condition grinding and milling, make super-finishing, gear-cutting and hobbing machines. Another important objective of this division is to procure old machines and repair them for further usage. A brand-new machine is very expensive whereas an old machine can be bought and repaired quite cheaply. These machines are for BFL plants only and are not sold outside the company.

A2 Line This shop is generally performed the final machining and painting of the products like crankshafts and front axle. Firstly the parting line grinding of the job is done through a robotic machine (special purpose machine). Then end grinding of the job is done followed by straightening and untwisting of the job. After this job is sent for visual inspection in MPI (Magnetic Particle Inspection) where job is magnetized and then seen under UV rays in order to find whether there is any crack is present in work piece or not.

International Trade Division (ITD)/Sales

The marketing and sale of products to overseas buyers is carried out by the ITD. BFL exports automotive parts to North and South America, Europe, China and Japan and non-automotive parts worldwide. There are teams to coordinate such sales, which are:Documentation and Logistics team: They handle all the documentation and transport of the products. 99% of the product sold overseas is shipped through cargo ships.Sales and Marketing team: This team is responsible for capturing clients and expanding the companys foreign clientele. It markets the companys products to potential buyers.The domestic marketing and sale of the product is carried out by the sales deptt. The procedure of sales deptt. Is similar to that of ITD starting from product purchase till the dispatch of the of the product to the customer.

Safety

It employs 39 safety engineers and 23 fire engineers which are trained in fire-fighting and safety measures should the need arise. Each department has an HSE (Health, Safety and Environment) Representative who is responsible for the safety regulations to be followed. For safety regulations to be employed, one needs HIRA (Hazard Identification and Risk Assessment). BFL employs Croners method for HIRA. Another lever is the BBS or the Behaviour Based Safety which divides workers behaviours into two categories Safe and Atrocious. Safe behaviour is what the worker should exhibit as is expected from him/her as per the guidelines.Each department is to carry out the following safety drills: 1.Plant safety inspection of one line per section per week.2.Identification of two hazards per line per section and implementation of its control.3.One safety meeting per month.4.Weekly tool box talk per line per section.5.Reduction of oil consumption by eliminating oil leakage and spillage.6.One department of fire audit per month.7.Fire Risk Assessment of one line per section per week8.One equipment audit per month.9.One safety Kaizen or suggestion per line per section per month.

Security

Bharat forge Ltd is in 86 acres Surrounded with 6 feet high stonewalls and barbed wire. There are 100 guards in total at Bharat forge working in groups of 30 in 3 shifts. The next step in the security is the access control where each of the employees are given the smart card and the visitors as well as the contract workers are given the manual or smart passes. There is DFMA and Security gate in order to check the access of the individuals coming inside the premises