Understanding the organizational operations of forging industry

Shaharu B.

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Understanding the organizational operations of forging industry

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Abstract

The forging industry forms an important part of the overall manufacturing activity in the country. Not many seem to know about it, but it influences people's lives everyday. The influence arises from the fact that many forged products have become almost indispensable in our daily lives. We will mention two of these. The crankshaft and front axle beam of the passenger cars and commercial vehicles and heavy metal parts of a railway train. Whatever the end use, essentially the process of forging involves the conversion of a block of metal into required products.

The forging industry much like its cousins, passed through some of its worst times in the recent past. After scaling the peak in FY 95, the industry began its downward slide. The direct cause was traced to the declining general economic activity and adverse conditions in the automotive sector. However, things have changed in the past one-year.

The presses seem to be back doing what they do best- pounding the metal. The noise apart, there are many, related more mundane, indicators pointing to this. The automobile industry is reviving, and the first quarter results are positive. All this is good news for the forging industry, which, in the not so distant past had found itself in a messy muddle shape. This conversion of metal block is done by application of pressure.

Forging is a manufacturing process where the metal is pressed, pounded or squeezed under great pressure into high strength parts know as forgings.

Introduction
Methods of forging
The production department
1. Process objects
2. Responsibilities
3. List of records
4. Process flowchart of the production department
5. Work instructions at production department
The maintenance department
1. Objective
2. Process objective
3. Type of maintenance
4. List of formats
5. List records
The quality assurance department
1. Major works watching
2. Quality objective of a company
3. Quality management systems
4. Sequence of process
Stores and purchases department
1. Objectives
2. Responsibilities of stores HD
3. List of work instructions
4. List of formats or records
The purchase department
1. Objectives
2. Responsibilities of HD purchase
3. Books of records
4. List of formats or records of purchase dept
The tools and die department
1. Objectives
2. List of formats or records
The planning department
1. Objectives
2. Responsibilities
3. List of work instruction
4. List of formats or records
The HRM department
1. Process objective
2. Responsibilities

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Extract

[...] TOOLS AND DIE DEPARTMENT Objectives: The main objectives of tools dept are as follows, Reducing production idle time due to non-availability of forging dies. Reducing forging idle time due non-availability of trimming tools. List of formats or records: The formats followed by the T&D dept are as follows, Forging die inspection report. Die history report. Coining die inspection report. Quality plan. Dovetail & dowel pocket inspection report. Tools history card. Punching and trimming electrode inspection report. Template inspection report. Tools and die issue register. [...]

[...] Any changes in the required planning will done as per the availability of dyes and tools, material or customer requirement in consultation with planning and T&D department Monitor the quality of manufacturing components, tools and equipments Receive the quality plans, process layouts, control plans, process flow chart, forging drawings for manufacturing and hand it over to shift in charge Plan and arrange for back up dyes and other facilities at all stages of process Identifying non conformances and taking appropriate corrective and preventive action in consultation with QA / MFE /MR If any identification required in the component drawing or any other document get it done through MR / concerned department by proper channels To identify the training needs of sub ordinates and workers Responsible for APQP, PPAP, and FMEA functions Raise requisition note to draw material / tools / consumables from stores preferably through Head of Production so that production will not be stopped Allocation of jobs to the operation as per day to day production plan Responsible for the quality of component produced Production process to be carried out as per work instruction/ control plan/ quality plan/ drawing etc. [...]

[...] Quality objective of a company: To satisfy the dynamic needs of our customers through adherer to systems, technology up gradation, and innovation. Quality management systems Sequence of process: Main process Sub process Management process/resources provision Planning Marketing Quality assurance Manufacturing engineering Calibration Purchase Maintenance Production H R M Stores Tools & Die STORES AND PURCHASE DEPARTMENT Objectives: The main objectives of the stores department are as follows, Reduction in regular consumable consumption. Reduction in time taken for raw material clearance from suppliers. [...]

[...] METHODS OF FORGING The first method is by heating a piece of metal to a certain temperature. Here we can have hot forgings, where the work piece is heated to over 1000 degrees Celsius, warm forgings, where the work piece is heated to about 400-500 degree Celsius and cold forgings. The second method is by application of pressure. The pressure applied to shape the metal can be done either through a hammer or through a falling mechanical weight or arm while in the case of press. [...]

[...] Carry out the operations in sequence as per the process layouts Collect raw material from stores as per work orders for processing. Allocate the job to operators as per the planning by shift in charge based on the work order. Operator to obtain first off inspection approval from the shift in- charge. Process the component in built quality after obtaining clearance from the process inspector. Maintenance Department Objective: Maintain the activities in an organization for functional accuracy. The main objective is to continue the work and reduce the idle time. [...]

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