The purpose of this research is to terminate the burr rejection on compressor driven pulley. The research is undergone using Minitab analysis software to design experiments with three factors and two levels, which is carried out by process capability analysis method. After that process, the experiment was further engaged in normalizing cooling process and optimized cooling process which help to know about the status of material hardness and its machinability. Hardness of forgings was higher at Optimized Conveyor Cooling (56 HRB 65to) and Hardness was getting lower at Normalizing Cooling (47 HRB to 58 HRB). Machinability of normalizing cooling forgings was not good as contrast to the Optimized conveyor cooling forgings. Sipoc approach was taken for detailed analysis. A significant amount of reduction in total machining rejection percentage in addition to the straight savings in incalescence, labour force and tool cost and rework cost. Study the effect of hardness improved material machinability status. © 2024 Elsevier B.V., All rights reserved.