The development of novel operations and their controlling forging faults is covered in the paper. In a standard procedure, rolling blocking finishing is used to complete the forging operation. In that research adding one more operation in between blocking and finishing with effective controlling some forging defects. In the forging operation, some shape product gets forged such as y – the arm suspension arm, etc. such type of protection some defects get formed which are bending, twisting miss mismatching, etc. In that paper, such type of defects were controlled by the addition of one more new operation in the forging process. Due to that operations also control defects in the coning operation and also improve the die life of the coning operation.