COMPLEX

ENGINEERING

FORGED,

MACHINED &

ASSEMBLED

PRODUCTS

Engineering the future of high strength

Key Figures

80

Customers

3

Manufacturing

Plants

Employees

1100

30%

Exports

5.8 million

Connecting rods

made in 2015

Our Operating System

Our Organization Structure

Kalyani Forge has a

very flat hierarchy

Bureaucracy has been eliminated

Speedy decision

making is encouraged

C-Suite

Value Stream

Manager

Associates

Senior

team

Milestones

Founded as

Ellora

Engineering

by Dr. Kalyani

Established

the Metal

Forms

Division

Established

the CNC tool

room

Cleared the

ISO TS 16949

audit

Set up a

dedicated

machining

division First in India

to develop

the fracture

split

connecting

rod

One of the

few Indian

companies

to establish

a cold

forging press

line

Cleared the

ISO 14001

Environment

Management

audit

1979

2000

2001

2002

2004

2005

2011

2012

Flash-less

Warm Forgings

Robust engineering

Lesser input material

Higher material

productivity

Near-net Shape Cold

Forgings

Superior surface finish

Remove waste from

processes

Eliminate the need for

machining

Superior Grain Flow

For Higher Strength

Parallel grain flow giving

high strength

Higher strength products

will allow for lighter parts

Technology

Our Technology

Reliable partner to experiment with

prototypes

Deep knowledge of metallurgy

Force study with Finite Element

Analysis

Aided in design stage for several parts

Product and die design with

AutoCAD &UG-NX

In-house die designing

Use of Electric Discharge Machining for die manufacture

Manufacturing simulation with

Deform Software

Co-Create With Us

Hot

Forging

Presses:

160-2500 T

Cold

forging

Presses:

350-650 T

Warm

Forging

Presses:

160-2500 T

Hot, Warm And Cold Under One Roof

Machining

Dedicated machining

lines for each customer

Single piece work flow

Laser fracture technology

Online tracking of all

quality parameters for conrods

Heat Treatment

Controlled Cooling

Normalizing

Iso-Annealing

Hardening & Tempering

Quenching(Oil & Polymer)

Tempering

Phosphating & Bonderising

Passenger

Vehicles

2W & 3W

Commercial

Vehicles

Construction,

Mining &

Infra

Agro

Passenger Vehicles

Wheel Hub

(inner & outer)

Tulips & Tripods

Outer Race & Inner

Race Connecting Rod

Cam Shaft Crank Shaft Balancer shaft Valve Bridge Piston Rocker Arm Clutch Hub

Gear Blanks

Differential Flange

CVT -

1. Primary Shaft

2. Secondary Shaft

Wheel Spindle Steering Knuckle

Commercial Vehicles

Connecting Rod

Cam Shaft Crank Shaft Balancer shaft

Valve Bridge Piston Rocker Arm

Tulips & Tripods

Outer Race & Inner

Race

Double yoke

Stub Axle

Wheel Hub

Clutch Hub

Gear

Wheel Spindle

2W

Connecting Rod Cam Shaft

Crank Shaft

Rocker Arm

Lower coordination &

admin costs

Local invoicing

Pull from warehouse

in Europe

Local Support

Deal in Euros

Kalyani Europe

Benefits

Our Global Footprint

Engineering the future of high strength

www.kalyaniforge.co.in