1. “Achieving excellence through IT and Automation a Bharat Forge Experience” Ninth ARC India Forum, Pune August, 2011 Achieving Operational Excellence Through IT and Automation Solutions
This presentation is intended to provide a corporate overview of ARC and the services we provide to the Manufacturing and Supply Chain communities.
Mukund V Mavalankar
Director Technical
Bharat Forge Limited
Photograph of Speaker

2. Global Profile of Kalyani Group Energy & Infrastructure.
Key Companies
in the Group
INDIA
CHINA
EUROPE
USA
Kalyani Steels Ltd
Kalyani Carpenter Special Steels
Kalyani Gerdau
Engineering Steel
CDP Bharat Forge GmbH, Germany
Bharat Forge Daun GmbH, Germany
Bharat Forge Aluminiumtechnik GmbH, Germany
Bharat Forge Kilsta AB, Sweden
Bharat Forge Ltd
Kalyani Thermal
FAW Bharat Forge
BF America
Forgings
Automotive Axles Ltd
Kalyani Lemmerz
Auto Components
BF Utilities
Kenersys India
BF Alstom
Khed Earth – The City
Energy & Infrastructure
Kenersys GmbH, Germany
Specialty Chemicals
Hikal Chemicals Ltd
Marsing, Denmark

3. Bharat Forge – Global Profile5 1
CDP BHARAT FORGE
Ennepetal, Germany 3 1 4
CDP FORGE
Daun, Germany 2 2 6
BF ALUMINIUMTECHNIK
Dresden, Germany 3
CAPACITY
135,000 tons
JV with FAW in China with 52% stake
Foothold into fastest growing market
Dual Shore Manufacturing
Manpower: 1500 People
BF AMERICA
Lansing 4
BFL
BHARAT FORGE KILSTA, Sweden 5 6
FAW BF (Changchun) Co. Ltd. Changchun, China
CAPACITY
365,000 tons
Worlds largest single location forging facility
Technologically advanced, flexible forging & machining facility
Proximity to fast growing Auto markets of China & india
Dual Shore manufacturing
Manpower: 4700 People
CAPACITY
200,000 tons
Production base close to the customer
Proximity to large marquee Customers
Dual Shore manufacturing
Manpower: 1060 People
CAPACITY
60,000 tons
Strong Foray in the largest auto market USA
Strong customer relationship
Dual Shore manufacturing
Manpower: 83 People
Capacity over 750,000 Tons per annum
Crankshaft machining capacity of over 1 ,200,000 nos.
Capacity to machine 500,000 FAB & 750,000 steering knuckles

4. Objectives
Till 1989 BFL was using manually operated pneumatic hammers for making forged parts.
Under the technology up-gradation initiative investment in two large completely Automatic forging lines.
The benefits envisaged
Improvement in Quality
Improvement in Productivity
Reduction in costs
Saving in Energy
Saving in Raw material

5. Layout of First Fully Automatic forging line

6. Scheme Sequential control for forging line

7. Integration of diverse programmable controllers.
Advantages of hierarchical control
Integration of diverse programmable controllers.
Ease of sequential control and programming multiple part types .
Ease of diagnostics.
Ease of monitoring complete line.
Consistent process parameters leading to consistent quality and higher OEE.

8. Second wave of automation 1997
Automatic, programmable screw press with controlled energy for every blow and regenerative braking.
Judicious use of combination of
Fully programmable Hydraulic Robots
First use of Electric robots,
Dedicated manipulators
Power and conveyors and walking beams.
Complete line integration with
Animated displays
Single Console Operation
First Use of Profibus
Hierarchical PLC controls
Use of Automatic application of Die lubricant

9. Up-gradation of Central Control 2011

10. Third wave of automation
The Kurimoto line was set up in This has taken BFL to next level of Automation. The salient features are
First Use of High speed Carbide saws
First Use of Transfer Presses
First fully integrated single flow line in BFL
Power and free cooling conveyor and over head gantries.
Robots 6 Axis all Electric
Reduced cycle time 8 sec untwisted/ 12 sec twisted cranks
Increased productivity
Mass production of passenger car cranks.

12. Next level of automation with remote I/Os

13. Case Studies in machined components division
Two case studies
Cooling tower Flow control through automation to achieve Energy Conservation.
Automatic Monitoring of machine Parameters & pop up error messages on machine screen.

14. Flow Control in Cooling tower
Cooling Tower is used for Cooling the Electrical switch-gear as well as quenching media.
In MCD1 we have used single cooling tower for more than 15 machines.
Before Implementation
Before
3000
Per Day Energy 3000 Units
Sudden Starting tend to reduce Switch-gear life. Also Flow control adjustment required.
No Control on Real Time Basis

15. Sense the number of machine running & decide the flow requirement
Flow Control in Cooling tower
COOLING TOWER
M/C
M/C
M/C
M/C
M/C
WATER IN
Temperature Sensor
M/C
M/C
M/C
M/C
M/C
Temperature Sensor
M/C
M/C
M/C
M/C
M/C
WATER OUT
Sense the Difference in Temperature of Incoming & outgoing lines & Decide the Flow & Exhaust Fan requirement
Sense the number of machine running & decide the flow requirement
MOTOR CONTROL
DRIVE PANEL
On Real Time basis switch On & off the Cooling tower in Lunch / Dinner time
Drive
PLC
Interface

16. After Flow Control in Cooling tower Sr No Parameter Before After* 1
1750
Sr No
Parameter
Before
After* 1
Power by the Cooling tower
120 KW
72 KW 2
Power Factor
0.8784
>0.94 3
Unit Consumption per month
65000 Units
35000 Units 4
Energy Cost (per Month)
` 325,000/-
` 175,000/- 5
Savings in Energy cost
46%
Per Million Contribution reduced by `1000 for MCD1

17. Manual monitoring of Machine Parameters
Machine Parameters are monitored for Predictive / Preventive Maintenance Plan.
This was done manually by the operator and relevant data was entered in the logbook.
Action Plan is communicated manually by each operator.
No interlock with machine Logic if any parameter is out of range.

18. Machine CNC System (To generate Fault on machine screen)
Machine Parameter Monitoring
Separate Control System Designed & programmed for automatic monitoring of Machine Parameters
Programmable Controller
Machine CNC System
Machine CNC System (To generate Fault on machine screen)
Machine
Oil Level
Temperature
Pressure
Preventive Maintenance

19. Summing up However we have challenges to overcome
Challenging Environment for Automation products
High Temperatures
High level of Dust, Scale, Graphite and water
High impacts and rough use
We have huge scope to automate our forging lines by
Automatic application of Die Lubricant
Automatic control of Die Temperature
Automatic monitoring of presses and motors
Automatic inspection of Forged parts with Vision systems
Automation of Post Forging operations
We have consistently used Robots and automation effectively to be
More Productive
More cost Effective
More Energy efficient
More Environmental Friendly