When hot forging components, wear can occur in the tool after a period of use, leading to incorrect geometry in the final component. This necessitates replacing the worn tool with a new one, which is costly. The current approach is to repair the tool using machining that removes the worn surface which is less efficient from a circularity standpoint. A more sustainable approach is to maximize the tool life by carefully adjusting the material and process parameters to slow the wearing process and repair without removing material as much as the cost is justified. Factors such as sliding distance, normal forces between the billet and forging tool, and the hardness of the tool all influence wear during forging. This study focuses on analytics of the process using measurements of the tool conditions and wear simulation based on Archard's law. The tool was analysed using stress, geometry, and hardness measurements. Several strategies to maintain or increase hardness, thereby extending tool life, are proposed. These include adjusting heat treatment before forging, modifying machining parameters, extending cooling time during hot forging, and replacing the current coolant with a more effective one.