In the field of Open Die Steel Forgings, there are only two companies in the country which are fully integrated, starting with steel making and ending with finish machining, manufacturing parts ready for assembly. To those familiar with this industry, naming Bharat Forge as one of the two would be a no brainer. But not many would be able to name the second, nor would they believe that it happens to be located in the eastern part of the country, far removed from the islands of manufacturing excellence in the more industrialised parts of the country; the company that proudly claims this distinction is Vikrant Forge Ltd (VFL), part of the rapidly progressing, Kolkata based Smithy Group.

Shunning the cheaper route of steel making through Induction Furnace, wherein sulphur and phosphorus content cannot be reduced, the group opted for the capital intensive but exacting steel making process by Electric Arc Furnace/Ladle Refining/Vacuum Degassing/Bottom Poured ingot route, capable of producing ultra clean steel, necessary for critical applications. The world class infrastructure set up by the group consists of steel melting, heavy forging, heat treatment, finish machining and testing facilities, all under one roof and a single management, with effective quality control.

An ISO 9001: 2008, ISO 14001: 2004 and OHSAS 18001 2007 certified company, VFL is relatively a young company, with a very humble beginning, which was incorporated in the year 1985 and commenced organised manufacturing only by 1989. But today it ranks among the top forging companies on a pan-India basis. "We had our sight firmly focused on our objective to become the best and to that end embarked upon a slow but steady and systematic growth curve, ploughing back the profits regularly into the company for creating infrastructure to keep pace with both technology as well as the growing market of a newly liberalised nation," says Manoj Chhajer, Director.

If the steel making process is ultra clean, forging is done through German Manipulators, and heat treatment in calibrated furnaces, finish machining which forms the last link of the strong process chain, is state-of-the-art. It comprises of modern 3-axis CNC machines capable of multitasking operations. The entire operation of the company runs on a customised ERP, leading to optimum and fast flow of information and execution.

With such good infrastructure, systems and quality human resource, approvals have come thick and fast, ranging from Works Approval by Lloyd's Register and ABS. This means that VFL facilities, processes, systems have been audited and certified for supply of forgings for marine applications. Besides approval from the best in the class overseas customers, VFL has approval from national heavy engineering giants, and Quality icons like IBR, NTPC, DRDL, DGQA and NPCIL winning the crucial nod for supplies to them / their sub-vendors as well.

If VFL entered the overseas markets comparatively later, that was because demand from Indian customers left nothing surplus for exports. "Only after our penultimate round of expansion was completed in the year 2008, creating enough capacity, did we start pursuing exports in right earnest," says Mr Chhajer. As a policy, VFL focused on the Quality conscious and tough but more rewarding West European market unlike most other Indian forging companies that took the easy route of low value, high volume traditional segment of oil-pipeline accessories to Middle East. "It was not easy, but with perseverance and by adopting world class practices, one by one we won over these demanding customers," adds Mr Chhajer.

If approvals came earlier, now the awards followed. With 35% of sales in fiscal 2011-12 earned from exports, VFL is already a Star Export House recognised by the Government of India. Among other awards that have come its way, VFL has recently bagged the EEPC National Award for highest growth in exports, presented on March 15, 2013 at a glittering function in Mumbai.

Within its range of single piece forging of 8 tonnes, the pivot products are: gear forgings for industrial and wind mill application; finished wheels and wheel assemblies for cranes/stacker-reclaimers/transfer cars, and finished shafts for cone and jaw crushers.

Though the current year has been difficult, impacting the industry in general and infrastructure industries in particular, VFL is still confident of posting a better top line with exports rising by almost 15% in the current year (2012-13). "The journey for VFL so far has been tough but very fulfilling. We are now poised for orbiting into the next trajectory of growth," concludes Manoj Chhajer. There is no reason not to agree.

(Manoj Chhajer, Director, Vikrant Forge Ltd. Mobile: +91-98308-88379. Email: manoj@smithy.in)