bharatforgeusa.com
The Excellence in Manufacturing Award winner honors the manufacturer that demonstrates exemplary practices across all areas of manufacturing – workforce development, sustainability, innovation, emerging markets/economic development and continuous improvement.
“Think Globally, Act Locally” Vision Delivers for Bharat Forge, the 2025 NCMEP Manufacturing Excellence Award Winner
Bharat Forge Aluminum USA, Inc., located in Sanford, North Carolina, commenced operations in 2021 and was the first greenfield aluminum forging plant built in the U.S. in over 15 years. This facility employs 200 workers who design, produce, and supply aluminum automotive components for luxury vehicles. The plant currently features top-of-the-line forging presses and a high level of automation and robotics to ensure the efficiency of its operations. Bharat Forge and its subsidiary Bharat Forge Aluminum USA Inc. are part of the Kalyani Group of companies headquartered in Pune, India.
Bharat Forge Aluminum USA, Inc. was selected to receive the 2025 North Carolina Manufacturing Extension Partnership Excellence in Manufacturing Award. The award honors the company for its impactful job creation, economic investment in North Carolina, and dedication to workforce development, continuous improvement, sustainability practices and global competitiveness.
Bharat Forge Aluminum, USA, Inc. exhibited these strengths, which led to their recognition:
- Job Creation: Bharat Forge Aluminum, Inc. creates numerous job opportunities in Sanford. The company has generated over 300 jobs in the region. These positions include roles for craftspeople, machine operators and technicians, providing a diverse range of employment opportunities for the local workforce.
- Investment in the Local Economy: Bharat Forge Aluminum, Inc. has already made a substantial investment of $160+ million in Sanford. This investment is not only for the construction of the aluminum forging plant but also for the development of infrastructure and facilities that support the local economy. The project is expected to add an estimated $787.1 million to North Carolina’s economy over 12 years. This significant economic contribution will have a lasting impact on the region’s growth and development.
- Workforce Development: Bharat Forge Aluminum, Inc. is committed to workforce development and training. By providing training and development programs for their employees, the company is enhancing the skill set of the local workforce, making them more competitive in the job market. The company actively promotes the regional workforce by collaborating with Central Carolina Community College and Sanford Area Growth Alliance. The company’s focus on advanced manufacturing techniques and technologies, such as Industrial IIoT and Six Sigma methodologies, ensures that employees are equipped with cutting-edge skills and knowledge.
- Continuous Improvement: Bharat Forge Aluminum, Inc. exemplifies the use of continuous improvement methodologies through the integration of Industrial IIoT (IIoT) and the Six Sigma DMAIC approach to enhance productivity and reduce downtimes in their Horizontal casting and forging machines. This systematic approach aligns organizational behaviors with a detailed action plan and timeline, ensuring that standards and work instructions are simple and visual for all work processes.
Examples of Improvements:- Real-Time Monitoring: Implementing real-time data analytics and diagnostics allowed for immediate identification and resolution of issues, improving overall equipment effectiveness (OEE).
- Reduction in Downtime: By harnessing predictive maintenance techniques, BFAL could set temperature threshold limits and monitor gas flow, significantly reducing downtimes.
- Reduction in Rejections: By continuous monitoring, the performance of the entire system was controlled to reduce rejections, improve quality and positive customer relations.
- Sustainability: Bharat Forge Aluminum, Inc. has been reducing its carbon footprint for over 40+ with health, safety, and environmental management systems that go above and beyond: Environmental Policy, Energy Policy, Sustainability Policy and ISO 14001 Environmental Management Systems Certification.
- Global Competitiveness: By establishing a state-of-the-art aluminum forging plant in Sanford, Bharat Forge Aluminum, Inc. is positioning North Carolina as a key player in the global automotive industry. This enhances the region’s reputation for advanced manufacturing and attracts further investment from other international companies.
– Vick Kheny, Vice President, Sales and Business Development
Bharat Forge Aluminum, Inc.’s investment in continuous improvement, advanced technology adoption, job creation, workforce development, community engagement and global competitiveness exemplifies Excellence in Manufacturing and drives significant economic growth and development in Sanford and North Carolina.
