IATF 16949 Aligned Automotive Forging Manufacturer

IATF 16949 Forging Manufacturer India | Automotive Certified Forgings | Shivam Forge

Shivam Forge is an automotive quality-aligned forging manufacturer — PPAP, ISIR, FMEA, Control Plan, SPC, and MSA documentation for automotive Tier 1 and Tier 2 supply chains worldwide. ISO 9001:2015 certified. IATF 16949 process-compliant. Supplying BMW, Mercedes, VW, JLR, Renault, and their Tier 2 supply chains with precision hot forgings from Rajkot.

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ISO 9001:2015

Current Certification

PPAP Level 3

Standard Submission Level

Cpk ≥1.33

Process Capability Target

8D / ISIR

Problem Resolution & First Article

Automotive Quality Standards in Every Forging

IATF 16949:2016 (International Automotive Task Force) is the global quality management system standard for automotive production parts and service part organisations. While Shivam Forge's primary certification is ISO 9001:2015, our quality management processes are designed and operated in alignment with IATF 16949 requirements — including PPAP (Production Part Approval Process), ISIR (Initial Sample Inspection Report), FMEA (Failure Mode & Effects Analysis), Control Plans, SPC (Statistical Process Control), and MSA (Measurement System Analysis). German, British, and French automotive OEMs and their Tier 1 suppliers (Bosch, ZF, Continental, Valeo) require this documentation from all Tier 2 forging suppliers.

IATF 16949 Aligned Quality Documentation We Provide

PPAP Level 3 — Production Part Approval Process

PPAP Level 3 is the standard submission for new automotive forging components — the most common level required by German, UK, French, and US automotive OEMs. Shivam Forge submits PPAP Level 3 packages containing: Part Submission Warrant (PSW), Design Records (drawings), Engineering Change Documents (ECR if applicable), Design FMEA (or Process FMEA for purchased components), Control Plan, Process Flow Diagram, Process FMEA, Measurement System Analysis (MSA/Gage R&R), Dimensional Results (100% of drawing callouts on 5 pieces), Material/Performance Test Results (EN 10204 3.1 MTC), Capability Studies (Cpk for critical characteristics), and Sample Production Parts.

ISIR — Initial Sample Inspection Report (VDA Format)

ISIR (Initial Sample Inspection Report) is the VDA (Verband der Automobilindustrie — German Auto Industry Association) equivalent of PPAP. German automotive OEMs (BMW, Mercedes, Volkswagen, Porsche, AUDI) typically require ISIR in the VDA format rather than AIAG PPAP format. Shivam Forge prepares ISIR documentation: complete dimensional measurement of all drawing callouts (5 sample pieces), material certificate (EN 10204 3.1), process description, measurement uncertainty analysis, and dimensional characteristic assessment to VDA 2 or ISO 8015 standards.

FMEA — Failure Mode & Effects Analysis

Process FMEA (pFMEA) is prepared for each new forging component family to systematically identify and mitigate potential failure modes in our forging process. Our pFMEA covers: material handling (wrong billet → wrong chemistry), forging temperature (under/over-temperature → mechanical property deviation), die wear (underfill, flash, dimensional drift), heat treatment (incorrect parameters → wrong hardness), and inspection failures. RPN values calculated; high-RPN items have mitigation controls in the Control Plan.

Control Plan — Production Monitoring

The Control Plan documents every monitoring step in our forging production process: billet incoming inspection (chemistry check against EN 10204 3.1), forging temperature monitoring (pyrometer, 100% of billets), post-forging dimensional check (key dimensions, sampling frequency), heat treatment temperature chart (100% of furnace loads), hardness test (3 points per piece, 100% of production), and final inspection (CMM or manual gauge, per sampling plan). Control Plan signed and submitted with PPAP.

SPC — Statistical Process Control

For production runs ≥500 pieces, SPC is applied to dimensions designated as 'critical characteristics' (marked CC or SC on customer drawing). Control charts (X-bar/R for variable data, np/p for attribute data) are monitored in real time. Out-of-control signals (Western Electric rules) trigger immediate line stop and root-cause analysis. SPC data is archived and provided to customer on request. Process capability targets: Cpk ≥1.33 (minimum), ≥1.67 for safety-critical characteristics.

MSA — Measurement System Analysis (Gage R&R)

Measurement System Analysis (Gage R&R) is performed for each measurement method used to control critical characteristics. We calculate %Gage R&R (Gauge Repeatability and Reproducibility) using the AIAG method: ≤10% = acceptable, 10–30% = conditional, >30% = unacceptable. For critical dimensions measured by CMM, Gage R&R is ≤5%. For manual gauges (micrometers, bore gauges), ≤15%. MSA results are included in PPAP Level 3 submission.

Automotive Forging Components We Supply

Chassis & Suspension Forgings

Steering knuckles, wheel hub blanks, stub axles, lower control arm pivot brackets, anti-roll bar forgings, and knuckle-to-strut mounting flanges. 42CrMo4 Q+T, C45E, or 34CrNiMo6 as specified. Critical geometry controlled by CMM. Grain flow documented by macro etch for safety-critical parts. PPAP Level 3 with all drawing callouts measured on 5 pieces.

Powertrain Forgings

Connecting rod forgings (I-section, fracture-split geometry), crankshaft blanks, camshaft forgings, gear blanks (17CrNiMo6, 20MnCr5, 16MnCr5), and transmission shaft forgings. Weight-matched connecting rod sets (±3 g). Fracture-split geometry achievable. EN 10084 / EN 10083 certification. PPAP with functional dimension Cpk ≥1.33 and Cpk ≥1.67 for bearing journal and big-end bore dimensions.

Braking System Forgings

Brake caliper brackets, brake pad carrier forgings, brake disc hats (aluminium alloy or C45 steel), and ABS sensor ring carriers. 42CrMo4 for caliper brackets; C45 or A356 for brake disc hats. Safety-critical part designation: Cpk ≥1.67 for all functional dimensions. 100% hardness test, 100% dimensional check on key dimensions. PPAP Level 3 with Process FMEA RPN ≤100.

Automotive Quality Standards in Every Forging

IATF 16949:2016 is the global automotive quality management standard that defines how forging suppliers must plan, control, document, and improve their manufacturing processes for automotive OEM supply chains. German automotive OEMs (BMW, Daimler/Mercedes, Volkswagen, Porsche, Audi) and their global Tier 1 suppliers (Bosch, ZF, Continental, Schaeffler, Mahle) require IATF 16949 certification or documented PPAP/ISIR capability from all Tier 2 and Tier 3 component suppliers. Shivam Forge's quality management system is built around PPAP, ISIR, FMEA, Control Plan, SPC, and MSA — the practical documentation requirements of IATF 16949.

For automotive forging suppliers, the critical quality deliverables are: PPAP Level 3 (for AIAG-format automotive buyers — JLR, GM, Ford, FCA) or ISIR in VDA format (for German OEM buyers — BMW, Mercedes, VW, Porsche), Cpk ≥1.33 (or ≥1.67 for safety characteristics), EN 10204 3.1 material certification with actual OES chemistry and mechanical test data, and SPC monitoring during production. Shivam Forge delivers all of these as standard for automotive forging programmes. Our precision closed-die forging process, CMM inspection capability, and in-house metallurgical lab (OES spectrometer, UTM tensile tester, Charpy impact machine, Brinell hardness tester) provide the measurement infrastructure required for PPAP Level 3 submission.

European automotive OEM supply chain quality expectations are particularly demanding. Volkswagen Group (VW/Audi/Porsche) requires VDA ISIR documentation and Cpk ≥1.67 for critical characteristics on safety parts (DS designation). BMW requires 8D response within 24 hours for field complaints and PPAP Level 3 with MSA ≤10% Gage R&R. Mercedes-Benz requires 100% dimensional check on features designated 'M' (mandatory inspection) in their drawings. Shivam Forge's quality team has experience with these specific OEM requirements and can align our PPAP/ISIR documentation to the customer's format on request.

For automotive buyers evaluating Shivam Forge as a potential forging supplier: we recommend starting with a Request for Quotation (RFQ) on 2–3 components, followed by tooling approval, first-article production, and PPAP Level 3 submission. Our standard PPAP lead time: 6–10 weeks from order to PPAP submission for new tooling. For existing tooling (standard forging profiles): 3–5 weeks. Air freight first-article to Frankfurt, Hamburg, Cologne, or any European airport in 2–3 days. Contact our quality team at sales@shivamforge.com — we'll provide a EUR quotation and PPAP plan within 24 hours.

Frequently Asked Questions

Is Shivam Forge IATF 16949 certified?

Shivam Forge is ISO 9001:2015 certified. Our quality management processes are aligned with IATF 16949:2016 requirements including PPAP, ISIR, FMEA, Control Plan, SPC, and MSA — the documentation required by automotive OEMs and their Tier 1 suppliers. We are pursuing IATF 16949 certification. ISO 9001:2015 with PPAP capability is accepted by many automotive Tier 1 and Tier 2 suppliers for forging input components.

What PPAP level can you submit?

We submit PPAP Level 3 as standard — the most commonly required level for new automotive forging components. Level 3 includes: Part Submission Warrant (PSW), dimensional results (5 pieces, 100% of callouts), EN 10204 3.1 MTC, Process FMEA, Control Plan, Process Flow, MSA/Gage R&R, Cpk data for critical characteristics, and sample parts. Level 1 or Level 2 available if specified by customer. ISIR in VDA format available for German OEM supply chains.

What is your process capability (Cpk) target?

Our Cpk target for critical characteristics is ≥1.33 as standard. For safety-critical characteristics (designated SC or CC on drawing), we target Cpk ≥1.67. Before production release, we run a minimum 30-piece initial capability study on critical dimensions. If Cpk ≥1.33 is not achieved, we investigate tooling, process parameters, and die wear before production release. Cpk data is reported in the PPAP Level 3 submission.

Can you submit ISIR in VDA format for German automotive buyers?

Yes. ISIR (Initial Sample Inspection Report) in VDA 2 format is available for German automotive OEM supply chain buyers. ISIR covers: drawing revision, characteristic list with measurement results (5 pieces), material certificate (EN 10204 3.1), process description summary, and characteristic assessment to ISO 8015 (actual vs tolerance). We work with your supplier development team to align the ISIR format to BMW, Mercedes, VW, or Porsche-specific requirements.

Can you supply safety-critical automotive forgings?

Yes — with appropriate documentation and process controls. Safety-critical forging components (designated DS, SC, or CC) require: Cpk ≥1.67 for safety dimensions, 100% dimensional check on critical features, EN 10204 3.1 material certificate with piece-level traceability, FMEA with RPN ≤100 for safety failure modes, and grain flow documentation (macro etch) for load-bearing geometries. Discuss your specific component requirements with our quality team.

Do you use SPC monitoring in production?

Yes. For automotive production runs ≥500 pieces, SPC (Statistical Process Control) is applied to critical characteristics. X-bar/R control charts are maintained during production with Western Electric run rules for out-of-control detection. Out-of-control triggers immediate production stop, root-cause investigation, and corrective action before resumption. SPC data retained and available for customer audit.

Can you supply automotive forgings to European OEM supply chains from India?

Yes. We currently supply automotive forged components to Tier 2 and Tier 3 suppliers in European automotive supply chains including BMW, Mercedes-Benz, Volkswagen, Porsche, JLR, Renault, and Stellantis supply chains. EN 10204 3.1, PPAP Level 3, ISIR, SPC, EN 10228 NDE for critical components. CIF Hamburg, Rotterdam, Felixstowe, or Le Havre in EUR or GBP. Same-day quotation response.

What 8D support do you provide for quality issues?

We use the 8D (Eight Disciplines) problem-solving format for all customer quality complaints. 8D report: D1 (Team), D2 (Problem description), D3 (Interim containment action), D4 (Root cause analysis — 5-Why, Fishbone), D5 (Corrective actions), D6 (Implementation and verification), D7 (Systemic prevention), D8 (Team recognition). Target: D3 within 24 hours of complaint; D4–D8 within 10 working days.

Why Choose Shivam Forge

Trusted forging manufacturer — Rajkot, Gujarat

Shivam Forge delivers precision hot-forged components from our integrated Shapar, Rajkot facility — covering forging, CNC machining, heat treatment, and quality inspection under one roof.

Hot forging from quality alloy steel billets (42CrMo4, C45, EN8, SS316L)
In-house CNC/VMC machining to drawing — ±0.05mm tolerances
Heat treatment — normalizing, hardening, tempering, annealing
CMM inspection and full EN 10204 3.1 material certification
Custom OEM forging from customer drawings — PPAP/ISIR available
Fast export from Mundra Port — CIF worldwide, FOB India
Export expertise — Europe, Middle East, Americas, Asia-Pacific