Presentation
Kalyani Group: Global Profile INDIA CHINA EUROPE USA Engineering Steel Kalyani Steels Ltd Kalyani Carpenter Special Steels Kalyani Gerdau Forgings Bharat Forge Ltd Kalyani Thermal FAW Bharat Forge Bharat Forge Kilsta AB, Sweden CDP Bharat Forge GmbH, Germany Bharat Forge Daun GmbH, Germany Bharat Forge Aluminiumtechnik GmbH, Germany BF America Auto Components Automotive Axles Ltd Kalyani Lemmerz Energy & Infrastructure BF Utilities Kenersys India BF Alstom Khed Earth The City Kenersys GmbH, Germany Specialty Chemicals Hikal Chemicals Ltd
Global Footprint 6 4 3 1 2 5 BFL 1 BHARAT FORGE Karlskoga, Sweden CAPACITY 200,000 Tons CAPACITY 365,000 Tons CAPACITY 135,000 Tons 2 3 4 5 6 CDP BHARAT FORGE Ennepetal, Germany BHARAT FORGE DAUN Daun, Germany BF ALUMINIUMTECHNIK Dresden, Germany FAW BF (Changchun) Co. Ltd. Changchun, China BF AMERICA Lansing (sales office) Production base close to the customer Proximity to large marquee Customers Dual Shore manufacturing Manpower: 1060 People 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 over 700,000 Tons per annum Crankshaft machining capacity of 1,200,000 Nos. Capacity to machine 500,000 FAB & 750,000 steering knuckles Skilled workforce of 7000 JV with FAW in China with 52% stake Foothold into fastest growing market Dual Shore Manufacturing Manpower: 1500 People
GLOBAL PRESENCE
Closed die forging - Equipment List Press Size No. of Presses Location Current Weight Range (Kg) Typical Parts Forged 16,000 MT 3 Sweden(1) & India(2) 100-200 I-beams, Crankshafts 12,500 MT 3 India (1) & China (2) 65-100 I-beams, Crankshafts 8,000 MT 4 India(1) & Germany (2) 40-65 Steering knuckles, Crankshafts, I-Beams 6,000 MT 3 India(2), N America(1) 20-50 Steering knuckles, Crankshafts, Con. rods, Lower control arms 5,500 MT 2 India 20-50 Crankshafts (Passenger car) 5,000 MT 3 4,000 MT 10 Sweden (1), Germany(1) & N.America(1) India(1), Germany (4), N.America(3), China(2) 10-50 5-20 Control arms, Steering knuckles, Lower control shoes, Track shoes, Crankshafts Steering Knuckles, Crankshafts, Con. Rods.swivel hubs, knuckles, control arms, heavy duty pistons, wheel carrier, Upper control arm, Trackshoes, Brackets 3,150 MT 3 China(3) 3-10 Connecting rods, Steering knuckles 2,500 MT 6 Sweden (1), Germany (1), N.America(1), India(3) 2-5 Con. rods, Transmission components, GET tips, Camshafts, Crankshafts, Knuckles, Pistons, Upper rear control arm. 2,000 MT 4 Germany (1) & China(3) 2-5 Tips, camshafts, knuckles, pistons 1,600 MT 5 Germany (1) & China(4) 2-10 GET tips Upsetters 2 India, China Hatebur AMP 70 1 China Total 49
Key figures 2011 Turnover (MEUR) 105 Employees 349 Steel consumption (1 000 t) 62
History Certification Competence Customers Production 1646 Bofors started operations with two water driven hammers 1894 Alfred Nobel buys Bofors 1914 The first order from Scania Vabis 1925 The first order from Volvo 1952 A new forging shop is built at the kilsta site 1980 The first order from MAN 1982-83 The 16 000 tone press line is built 2005 Bharat Forge Ltd buys Kilsta
History Certification Competence Customers Production
Improvement teams History Certification Competence Customers Production Together with our customer we aim to create cross functional improvement teams. Example of improvements: Design changes to optimize machining Optimize the tolerances Optimize design to decrease forging weights Adapt the forging to improve the production process at customer Optimize the supply chain
History Certification Competence Customers Production Volvo Renault Trucks Mack Trucks MAN Scania IVECO Hema Sandvik Feuer/GM/MTU Poldi/Agco Sisu Power
Heavy forgings PRODUCTION Forging presses Die manufacturing Heat treatment Finishing Machining Heavy forgings (16 000 ton press 100-250 kilo) Crankshafts for heavy duty engines Front axle beams for heavy vehicles
HEAVY Medium forgings FORGINGS PRODUCTION Forging presses Die manufacturing Heat treatment Finishing Machining Medium forgings (5 000 ton press 10-50 kilo) Crankshafts Steering knuckles Transmission parts Rock drilling equipment
Light forgings PRODUCTION Forging presses Die manufacturing Heat treatment Finishing Machining Light forgings (2 500 ton press 2-10 kilo) Steering arms Crankshafts
Die manufacturing PRODUCTION Forging presses Die manufacturing Heat treatment Finishing Machining High speed milling Grinding Inspection Welding Nitro carburizing Assembly
Heat treatment facilities PRODUCTION Forging presses Die manufacturing Heat treatment Finishing Machining Continuous furnaces and batch furnaces for hardening, normalizing and isothermal annealing
Finishing facilities PRODUCTION Forging presses Die manufacturing Heat treatment Finishing Machining Shot blasting to remove scale Inspection Crack detection
Machining PRODUCTION Forging presses Die manufacturing Heat treatment Finishing Machining End milling and mass centering of crankshafts Machining and painting of chassis components