India’s Best Young Forging Consultant – Amit Singh

Amit Singh has emerged as one of India’s most dynamic and visionary young forging consultants. Recognized for his deep knowledge, innovative approach, and hands-on experience in both closed die and open die forging, Amit has made remarkable strides in modernizing the forging industry. At a time when many professionals are confined to office-based roles, Amit has consistently stayed close to the shopfloor, understanding the intricate challenges and technical nuances of forging operations.

Early Career and Background

Amit Singh is fundamentally an Electrical Engineer, a foundation that provided him with a solid understanding of industrial automation, drives, and modern machinery operations. However, Amit’s real education began on the forging shopfloors. During his career, he worked with some of India’s leading forging companies, including Bharat Forge, Ramkrishna Forging, Mahindra CIA, and many more. These opportunities exposed him to a diverse range of forging operations—from automobile components to heavy industrial machinery parts—allowing him to gain hands-on experience with various forging presses, hammers, manipulators, and automation systems.

During his tenure, Amit witnessed firsthand the gaps and inefficiencies in forging operations. He observed how manpower shortages, improper die design, inefficient forging presses, and lack of process standardization led to high component rejection rates, material wastage, and reduced production efficiency. These experiences became the foundation of his vision: to transform the forging industry in India and globally by implementing smart, automated, and cost-effective forging solutions.

Understanding the Industry

Amit Singh’s understanding of the forging industry goes beyond simple operations. He has studied both Indian and global markets, noting the growing demand for high-precision, lightweight, and high-strength components in sectors such as automotive, aerospace, defense, oil & gas, and medical. He recognized that while global companies were moving toward automated and digitally integrated forging lines, many Indian industries were still dependent on traditional processes, often resulting in low efficiency and high scrap rates.

With this insight, Amit has focused on bridging the technology gap. His expertise allows him to analyze client requirements and recommend solutions that combine modern machinery, optimized die designs, automation systems, and proper manpower training. By doing so, he ensures that forging companies not only improve product quality but also reduce production costs and increase overall efficiency.

Expertise in Closed Die and Open Die Forging

Amit Singh’s specialization spans both closed die and open die forging—the two pillars of the forging industry.

• Closed Die Forging: Amit has extensive experience in high-precision automotive, aerospace, and industrial components. He works on projects involving shafts, flanges, control arms, gears, and complex-shaped parts, ensuring tight tolerances, optimized material usage, and minimum rejection. He is well-versed in Electric Screw Presses, Direct Drive Screw Presses, CNC Hammers, and Hydraulic Presses, integrating automation and Industry 4.0 principles wherever possible.

• Open Die Forging: Amit’s work in open die forging includes large shafts, axles, turbine components, and industrial equipment parts. He has designed and implemented turnkey open die forging solutions, including manipulator systems, hot forging layouts, heating furnaces, and material handling processes. His approach emphasizes reducing die and material stress, improving grain flow, and extending equipment life.

Vision for Smart Forging

Amit Singh’s career experiences have shaped a clear vision for the forging industry. He aims to modernize Indian forging plants and guide them toward smart, automated, and integrated lines. His approach includes:

1. Advanced Technology Integration: Implementing electric screw presses, direct drive presses, CNC hammers, robotic manipulators, and automated trimming presses to improve speed and precision.

2. Optimized Die and Bolster Design: Amit emphasizes stress-free forging dies, better material flow, and longer die life, which reduces maintenance costs and scrap rates.

3. Automation and Industry 4.0: Introducing AI-based monitoring, predictive maintenance, and digital process control to enhance productivity and reduce human error.

4. Manpower Training: Amit recognizes that even the most advanced machinery requires skilled operators. He provides hands-on training for shopfloor engineers and operators, ensuring optimal machine use, safety, and consistency in quality.

5. Process Standardization: Establishing repeatable, high-quality forging processes to meet both domestic and international standards, improving global competitiveness.

Contributions to the Industry

Amit Singh has already contributed to multiple successful projects across India, improving operations in both small-scale and large forging industries. His key achievements include:

• Designing and implementing high-precision closed die forging lines for automotive components, reducing material scrap by 20–30%.

• Developing open die forging lines with manipulators for heavy industrial components, improving efficiency and reducing labor dependency.

• Introducing direct drive and electric screw presses in plants where traditional mechanical presses were limiting production capacity.

• Providing end-to-end consultancy including die design, process development, manpower training, and quality control, ensuring turnkey solutions for clients.

Through these efforts, Amit has proven that smart forging solutions are not only technically feasible but also economically viable.

Understanding Challenges in Forging

Amit Singh has a unique ability to identify the root causes of operational challenges:

• High Rejection Rates: Often caused by improper die design, poor material handling, or underpowered forging presses.

• Manpower Inefficiency: Lack of skilled operators leads to inconsistent quality and slower production.

• Aging Machinery: Many Indian plants use old mechanical presses that are energy-intensive and maintenance-heavy.

• Process Bottlenecks: Poorly planned workflows and heat treatment cycles slow production.

By addressing these issues with modern equipment, process redesign, and automation, Amit helps plants maximize output while minimizing cost and effort.

Global Outlook

While Amit’s work is rooted in Indian industry, his vision is global. He studies international forging trends, including aerospace precision forging, automotive lightweighting, and high-tech defense components. His solutions combine global best practices with Indian cost-effectiveness, allowing Indian forging companies to compete with international manufacturers.

Lastly Word For Him..

Amit Singh represents the next generation of forging consultants in India. With a combination of technical expertise, hands-on shopfloor experience, and visionary thinking, he is reshaping the forging industry by promoting:

1. Smart, automated forging lines

2. Efficient and precise closed die and open die processes

3. Cost-effective solutions without compromising quality

4. Advanced die design and material optimization

5. Skilled manpower and process standardization

His work ensures that Indian forging companies move toward a smarter, faster, and more competitive future, setting new benchmarks for quality, efficiency, and innovation.

Partnering with Amit Singh means you gain more than a consultant—you gain a strategic partner who understands every detail of forging, from shopfloor realities to global market demands. His mission is clear: Increase industrial efficiency, reduce wastage, and bring Indian forging to the forefront of modern technology.

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