There is a requirement of Computerized Vision Inspection System that is Cost Efficient and can fit into organizational business cases. Inspection for specific parts is important and critical in matters of finance and final quality of the product. Currently, Bharat Forge uses 2 methods for inspection that is; manual vision inspection by a person, and magnetic inspection. The company faces a huge loss if a part is rejected as the rejection of one part may lead to the whole batch getting rejected. The company is in need of a Computerized Vison Inspection System that identifies issues in matter of quality or defects so they can be rectified and rejection can be prevented. There is already an existing vision inspection system in use however has following challenges 1.) The system is unable to differentiate between valid defects and foreign matter such as water stains and dust particles. 2.) The system that is currently in use is expensive.

There is an increasing need for efficient and intelligent support systems for CEOs and CFOs in managing and extracting valuable insights from vast amounts of data and information. Bharat Forge is looking to address this need of a Virtual Assistant (Co-Pilot) that can receive, process, and provide actionable insights from various existing data sources. This Virtual Assistant (Co-Pilot) is intended to serve as an indispensable tool for executives, offering information aggregation, analysis, and reporting in an easily accessible and conversational manner. The Virtual Assistant should be able to work on voice command with usage of everyday language.

EV’s necessitate the conversion of power between AC and DC states during both charging and  operation. While charging, AC power must be converted to DC to charge the vehicle’s battery, and  during operation, the stored DC power must be converted to AC to drive the motor. Hence there is a  conversion between AC & DC & back to AC by using multiple components (Charger & Inverters)  

Even though for most of the new product designs, we already have another similar part being manufactured, still the overall cycle time is very high and has no re-usable components. The current New Product Development process used by the partner is time consuming and is also not cost efficient. Currently, whenever a new product is designed, the consumer provides the company with required details such as design, dimensions etc. The current New Product Development process is time consuming as there is no base of any kind to build upon although they have the required information/data available, the cost increases along with the time taken for the development for a new product. Whenever a new product is being developed, 40% to 50% of the time can be reduced by building a base for this product by using available information from same or similar products that have been previously designed. 

Despite having a repository of information and data from past product designs, the current NPD process lacks re-usability and efficiency. Each new product is designed from scratch, resulting in extended cycle times and increased costs. Bharat Forge is looking for an AI Algorithm that can access the previous data available to them and build a type of base to build upon to minimize the time and effort spent on the New Product Developmet process which automatically reduces the cost spent during the process.

The main unit contains huge mechanical presses. There is a critical need to reduce downtime and production losses associated with breakdowns in its mechanical presses. When a component fails, such as a Pitman crack, the rod crack, bull gear bearing failure, motor failure, or friction and misalignment issues, it not only results in substantial downtime but also disrupts production schedules. The component which is broken down takes a long time to be replaced which automatically leads to production loss. The mechanical press potrays certain features which indicate the break down such as change in temperature, pressure, force exerted etc. The company is in need of AI based algorithms that learn & analyzes the indicators and predicts a breakdown so the breakdown can be expected beforehand and prevented.

As EVs increasingly rely on high voltage batteries (ranging from 350V to 650V) to power various accessories, there is a pressing need for innovative solutions to optimize power transfer, enhance efficiency, and reduce component size and cost. All accessories of an EV require power at different voltage and at different forms (AC / DC). The basic source of this power is the high voltage battery. Inverters and converters are used between the accessories and the battery pack to enable this power transfer.