Bharat Forge Limited, one of India’s foremost engineering and manufacturing powerhouses, specializes in forged and precision-machined components for diverse sectors. With a robust global footprint spanning India, Germany, Sweden, France, and the United States, it stands as one of the country’s top auto component exporters, boasting a net worth of $3.9 billion and an annual turnover of $1.5 billion. Complementing this strength, JS Autocast Foundry India Pvt. Ltd. contributes significantly with a production capacity of 120,000 LMT of ductile iron (DI) castings and a machining capability of 20,000 MTPA, reinforcing the group’s integrated manufacturing excellence.
For Bharat Forge’s strategic Machining Expansion Project in wind gearbox castings, the company needed a domain expert to critically assess the business case, technical feasibility, and long-term viability of the initiative. Ramwin Engineering was brought in to lead this high-impact evaluation—ensuring every decision was grounded in deep industry insight and aligned with global manufacturing benchmarks.
- RamWin Engineering Services worked on developing a comprehensive business case for the machining expansion project, addressing the following key aspects:
- Product Mix Study
- Drawing Analysis and identification of CTQs (Critical to Quality parameters)
- Cost-Effective Machining Process Evaluation
- Definition of Machine Specifications
- Identification of suitable Machine Suppliers
- Conducting Technical Discussions with suppliers
- Obtaining and analyzing RFQs (Request for Quotation) from suppliers
- Cycle Time Analysis for the new process
- Capacity Analysis
- Formulation of a business case, including calculations for ROI (Return on Investment) and IRR (Internal Rate of Return)
- Evaluated production trends and forecasted demand
- Technical Analysis & CTQ Identification
- Process & Technology Evaluation
- Specification Development & Supplier Mapping
- Supplier Engagement & RFQ Management
- Cycle Time & Capacity Modelling
- Business Case Formulation
- Implementation of a Cost-Effective Machining Process
- Capital Investment Reduced to One-Third compared to European equivalents
- Strategic Supplier Engagement and Value Engineering
- Efficient and Proven Project Execution
- Strong ROI and Industry-Aligned Financial Returns