Abstract: The objective of this paper was to investigate the various forging defects that occur in a forging industry that causes high rejection rates in the components and this paper describes the remedial measures that can reduce these defects in the hot forging. The investigation was done with the help of quality assurance department within the industry. The various defects that occur in the components during forging are identified. The result indicates that the rejection rate in the company was more than five percent of the total productions made each month. The defects in the forged components includes the lapping, mismatch, scales, quench cracks, under filling etc. In this paper, it describes the remedial actions that to be done inorder to reduce the rejection rates. The remedial actions includes the proper use of anti scale coating, venting process to prevent the under filling, the simulation software for determining the material flow, proper lubricant (espon lss) instead of furnace oil etc.