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Manufacturing · Software for hot forging companies

Know which billet, die and furnace run made each forged piece.

Hot forging turns a heated billet into a shaped part under a hammer or press. The software ties each forged piece to its mill heat number, die set, strike count and induction heater temperature, so laps and cold shuts trace to one die. Normalising, shot blasting and magnetic particle inspection follow on the same record.

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At a glance

A hot forging shop buys bar from a steel mill, saws it to billet weight and heats it in an induction coil or gas furnace until it glows orange. A hammer strikes it between dies. Flash is sheared off in the trim press. The part is cooled, normalised and descaled.

Hot forging software follows the billet from the mill certificate through the heater, the blocker and finisher impressions and the trim press, counting strikes against each die set. Scrap is booked by cause.

How the work runs today

Customers send a forging drawing with a grade such as C45 carbon steel, 42CrMo4 alloy steel or 304 stainless. The shop works out billet weight plus flash and scale loss, prices the die and quotes a piece rate. Dies are sunk in the die shop, tried out on a hammer and held against the customer part number. Bar arrives with a mill test certificate and a heat number, and the saw then cuts it to billet weight.

On the line, the heater operator watches billet temperature on a pyrometer while the press operator strikes each piece in the blocker and finisher impressions. Flash goes through the trim press. Forgings are cooled, normalised and shot blasted. Then they are checked for dimensions, hardness and surface cracks by magnetic particle before packing with the heat number and the report for the customer’s goods inward bay. Short fills and laps mark a worn die. It goes for repair.

Where it breaks

What goes wrong for hot forging companies without a proper system.

Die life is judged by feel

Strikes per die are noted on a clipboard, if at all. A die that should have gone to the die shop for re-sinking keeps running, and the scrap bin fills with laps, cold shuts and short fills.

The mill heat number is lost after cutting

Bar is sawn into billets and the mill certificate stays in a file, so when a forging cracks in service nobody can say which heat of 42CrMo4 it came from. The saw bay keeps no record.

Scale and flash losses are guessed

Billet weight, forging weight and trimmed flash are never set side by side on the same job. Scale loss from the furnace is guessed, so the quoted material cost drifts away from the real one.

Heat treatment and finishing are tracked loosely

Normalising and shot blasting run in batches, so a load of connecting rods or flanges can leave the gate without its hardness readings attached. The customer finds out at goods inward.

Dies belong to customers and wander

Die sets are sunk for one part and kept for the customer, and where each set sits on the rack is written nowhere. Nobody counts the blows. Nobody owns the answer.

What the software does

What we would build for hot forging companies.

Named the way your team already talks about the work. We start with whichever part the audit shows is costing you most.

Billet and bar receipt

Receive bar by grade, section and mill heat number, then saw billets to a recorded weight so each billet keeps the heat it was cut from, with its certificate.

Die register

Hold each die set against its part number with strikes counted, re-sinking history and life remaining. Any die near its limit is flagged to the die shop before it fills the bin with scrap.

Heating and forging log

Record induction heater or furnace temperature, the press or hammer used, blows per piece and the operator shift against each lot, so a bad run can be placed.

Trim, heat treatment and cleaning

Pass forgings through the trim press, normalising or quenching and tempering, and shot blasting, with quantities and rejects booked at every step. Nothing moves on unrecorded.

Crack and hardness inspection

Log magnetic particle, Brinell hardness and dimension results by lot, hold any failing lot, and print the inspection report with the heat number on it.

Yield and scrap reporting

Compare billet weight with forging weight, flash and scale loss to see the true material cost of each part against the quote. Job by job, the gap shows.

Dispatch and invoicing

Each load of crankshafts and flanges leaves against its forging lot, with the billet heat number and mill certificate clipped to the delivery note. Billing reads the lot entry the stores clerk closed at the gate, so the invoice quantity cannot drift from what was counted onto the truck. Papers match the load.

Before you talk to a supplier

A requirements checklist for hot forging companies.

What to cover, which reports to ask for and what to put to every vendor, ready to print or save as a PDF.

Open the checklist
Ready product

A product already built for hot forging companies.

It is adapted to how your business works before it goes live, and anything your trade needs that it lacks is added then.

Hot Forging Company Management Software

Billet stock by mill heat, die strike counts, induction heating and press logs, flash trim, normalising, magnetic particle inspection and dispatch for hot forging companies.

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Solutions inside

The business modules hot forging companies use most.

Each one is also available on its own, or inside a system built for you.

Services

The services behind it.

Business Process Automation

Approvals, reminders, follow-ups and reports that run on their own instead of on someone remembering.

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ERP, CRM and Business Software Implementation

One record of stock, orders, customers and accounts, set up so your team opens it every day.

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Data Migration and Moving Off Spreadsheets

Data migration and spreadsheet replacement covers auditing existing files, cleaning and deduplicating records, loading them into a new system and reconciling the loaded result against known totals. Both systems then run side by side before cutover. Originals stay untouched.

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How it works

How the work runs from Bengaluru for your city.

  1. 1

    The audit, by call

    A screen-share and a look at the sheets, accounting reports and WhatsApp groups your team uses. No travel needed.

  2. 2

    A written proposal

    Scope, what we build first and the cost, agreed in writing before anything starts.

  3. 3

    Build in short rounds

    Working screens shared every few weeks. Your team tests them from your own office.

  4. 4

    Go-live, in person when it helps

    For data migration and training we can come to your city. Travel is agreed in advance.

  5. 5

    Support online

    Fixes, changes and hosting handled remotely by the same team that built it.

Our work

Software we have built and run.

We only name clients whose work is published. These are systems our team designed, built and supports.

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Common questions

Questions hot forging companies ask before they call.

Is every strike on a die counted?

Yes. Each forging lot books its blow count against the die set, and the register shows the total since the last re-sinking. A limit you choose raises a flag before the next lot starts.

Do we need hammers and presses both?

No. Hammer lines, screw presses and mechanical presses are set up as separate work centres, each with its own hourly rate and billet size range, so costing stays honest.

Is the mill certificate tied to each forging?

Yes. The bar heat number is carried through sawing and forging, so a finished lot shows the heat and certificate it came from, even after mixed batches in the shot blaster.

What about forgings we send out for machining?

They leave against the job as a subcontracted process and return by quantity. Rejects found on return, such as oversize bores or decarburised skin, are charged back to the vendor and lot.

What happens after I share my requirements?

An engineer reads what you send and replies within one business day. We then look at the software, spreadsheets and WhatsApp groups your business runs on today and write down what works, what slows your team down and what is missing. A demo login, a screen-share or a few screenshots are enough. You get a short written summary ordered by priority, with no obligation to hire us afterwards.

How much will the software cost?

We don’t publish a price, because it depends on what the system has to do. That first review settles the scope, and the cost goes into a written proposal before any work starts.

Related

Related industries.

Category

Part of a wider group.

Talk to us

Tell us how your business runs today.

A few lines on your spreadsheets, software and WhatsApp groups is enough. We reply the same working day.

  • No obligation
  • A reply within one business day
  • Your details stay private

Start with your requirements

Seven short steps that tell us what you need. An engineer reads them before getting in touch.

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