THE COMPANY

Hindustan Aeronautics Limited is a “NAVRATNA” Defence Public Sector Unit and is presently ranked 34th among the global defence aerospace companies. Founded in 1940, HAL has 16 Production Divisions, 3 Maintenance Repair and Overhaul Divisions and 10 R&D Centres, spread across the country.  The product portfolio, originating from both indigenous in-house design and license production, meets almost all the requirements of Indian Defence Services through Fighter aircraft, Trainer aircraft and Helicopters. It has witnessed a steady growth over the years and achieved a turnover of Rs.10260 Crores(2 Billion USD) in 2008-09.

OUR MISSION

“To become a globally competitive aerospace industry while working as an instrument for achieving self reliance in design, manufacture and maintenance of aerospace defence equipment and diversifying to related areas, managing the business on commercial lines in a climate of growing professional competence.”

HELICOPTER MRO DIVISION

OBJECTIVE

To  create a customer centric organization and provide focused impetus to the growing MRO activities on rotary wing aircrafts including ALH (DHRUV) & New Projects , a dedicated Helicopter MRO Division has been established within the Helicopter Complex.  The Helicopter MRO Division is operational since Dec 06 with focus on robust customer support for the delivered helicopters.

HELICOPTER MRO DIVISION

• The Helicopter MRO Division is operational since Dec 06 providing end to end customer support for the delivered helicopters.

• The Division is presently providing MRO support for ALH (conventional cockpit and IADS configurations) and Seaking  projects. Future projects include ALH-WSI, LCH, RSH, LUH and IMRH.

• Strategies are put in place to sustain an optimum level of serviceability viz. INSITU servicing at customer bases,

• Effective LRU Management, Supply Chain Management, Reliability Improvement, Lifed Items and Obsolescence management, Development of private vendors for repair support in India  are some of the initiatives put in place to provide life cycle support..

• The Division is ensuring continuous improvement by adapting lean culture, Kaizen and TWI approach to achieve customer delight. The Division is ISO 9001:2000 certified and is on its way to get AS 9100 accredited soon.

HELICOPTER MRO INFRASTRUCTURE

The Division has invested Rs 54 Cr. to set up world class MRO Infrastructure & facilities and Rs. 271Cr. for creating in-house repair facilities for LRUs and rotables of ALH.  It has progressively inducted qualified engineers and technicians to provide high serviceability for Indian and Overseas customers.

NEW HANGARS

• New infrastructure dedicated for MRO under construction.
• Assembly hangar of 95,000 Sqft. with support hangarage of  40,000 Sqft  to cater to indigenous H/c MRO programs.
• A new Division replicating the model of the present Division for MRO of  h/c’s of foreign origin planned as a green field project.
• Present MRO Division has inbuilt capacity to handle 60 medium lift H/c per year.

ALH: A RELIABLE, VERSATILE AND ALL WEATHER HELICOPTER

ALH-IN MUTI ROLES

Ø       Logistic air support

Ø       Search and rescue

Ø       Under slung load

Ø       Ship deck landing

Ø       Casualty evacuation

Ø       Air observation post

Ø       Communication duties

CAPABILITIES

ROBUST CUSTOMER SERVICE ORGANIZATION

• Customer interface provides continuous connectivity with customers on  24x7 basis for Technical support.

• Spares management system to procure, store and issue spares for AOG/warranty management and as per Customer needs.

• Training team provides training at HAL as well as at customer bases.

• Adequate Ground Support Equipments & Ground Handling Equipments at all Customer Bases.

•  Extensive Bay servicing facility at all Customer Bases to improve testability, fault isolation and correction.

• Multiskilled customer support teams permanently positioned  in all operating bases.

• Cross Functional Reliability team to analyze field failures, provide technical solutions and implement the solutions for improved serviceability of delivered Helicopters.

• Servicing of Helicopters at Customer Bases for 500/750hrs to increase Helicopter availability.

• Facilitation of customer to undertake servicing and carry out repairs at bases to enhance serviceability.

Triumphant team of  MRO /customer  at  Manasbal after completing 500hrs servicing in a  record time of 38 days

HAL PRODUCT SUPPORT TEAM AT CUSTOMER BASES

Team at Ecuador and at Mauritius are already operational.

MRO SHOPS

•         Present MRO Division has inbuilt capacity to handle 60 medium lift h/c per year.

•          Assembly hangar of 95,000 Sqft. with support hangarage of  40,000 Sqft  to cater to indigenous h/c MRO programs ( ALH, LUH, LCH).

•         Good technical support team comprising Design Liaison & Methods.

•        Established Quality assurance procedures.

•         Excellent GSE/GHE Equipment support to carry out Helicopter servicing.

•          Portable Computerized Loom testing facility for identification of looms faults.

•          Zone wise operation concept to improve the cycle time.

•   Full fledged Repair /Overhaul facility in MRO and other Divisions of  HAL for over 200 LRUs of ALH.

                                                                        EQUIPPING WORK UNDER PROGRESS                                                IDS UNDER INSTALLATION

                                                                                        CNI  TEST BENCH                                                                            BACARA  TEST BENCH

UNIVERSAL TEST RIG

BAY SERVICING/GSE/GHE SUPPORT AT CUSTOMER BASES

As part of bay servicing support Electrical, mechanical and avionic labs have been established at the operating bases.

•  Some of the important repair facilities established are

•           Avionic System-         -    Flight data and cockpit voice recorder, Glass cockpit & Automatic flight control  system.

•     Communication &       -    Doppler, Weather Radar, V/UHF Navigation System                  

•     Hydraulic & Fuel         -    Actuators, Fuel Pump & Fuel tanks

•     Electrical System-      -    Cockpit instruments, AC  & DC systems

•     Power plant system    -    Engine, IGV actuator  

For easy maintenance and  fault isolation of LRUs and Helicopters at customer bases, extensive Ground Handling Equipments, Ground Support Equipments and Bay Servicing facilities are provided at every customer base. Improved miniaturized AC/DC ground power equipments, Hydraulic trolleys, ladders, Engine Start Pack have been provided.

                                                                           DIESEL AC/DC GROUND POWER UNIT                                         GLASS COCKPIT  TEST BENCH

                                                                       DIESEL AC/DC GROUND POWER UNIT                                      PETROL DRIVEN HYDRAULIC TROLLEY

                                                                               MINIATURISED LADDER                                                        ENGINE START PACK

CALIBRATION

The Division has established Calibration procedures and agencies for Calibration of all test equipments, GSE/GHE and tools used for repair activities. The in-house calibration facility for the general purpose test equipments is under progress and will be completed by Dec-09.

INTEGRATED MATERIAL MANAGEMENT

Availability of materials and spares for servicing at the right time & right place is essential for effective repair / overhaul support.. Recognizing this, a strong MRO IMM organization has been  put in place with separate cells catering to warranty support, float management, customer order & recycling of LRUs.

TECHNICAL SUPPORT

Onsite technical support teams with multiskilled technicians are positioned in each of the operating bases backed by dedicated documentation and Design Liaison cells within the Division to ensure fast response . Modification upgradation and compliance is effected by modification implementation cell and methodising groups

.

RELIABILITY AND MAINTAINABILITY

A Cross Functional Reliability and Maintainability Cell consisting of representatives from Design, Production and MRO Divisions is in place working on field failure data and internal failure data. This team analyses field failures and internal reports to identify areas for technical improvements. Implementation of solutions in delivered Helicopters and monitoring the efficacy of improvements is also carried out by this cell. FRACAS software tool is used for effective failure analysis, reporting and corrective action. Reliability improvement actions in LRUs , Engines and IDS of ALH are identified. LRU modifications have  resulted in significant reduction in LRU failures. Replacement trend per 100 hrs has considerably reduced.

OBSOLESCENCE MANAGEMENT

Effective obsolescence management is essential for life time support of the fleet. As fleet ages obsolete components need to be continuously reviewed and alternative actions need to be put in place much before the fleet gets affected. The team has identified four Avionic systems for alternate solutions during the year.

QUALITY POLICY

We at Helicopter MRO Division strive to be a leading Maintenance, Repair and Overhaul agency for helicopters and helicopter systems with the Commitment to achieve customer satisfaction by on time delivery of quality products and services and continually improving our quality management system.The Division is ISO 9001:2000 certified and is on its way to get AS 9100 accredited by Dec 09.

SPECIAL INITIATIVES

LEAN  ACTIVITIES

Kaizen events are organized in the Division to bring specific improvements in Productivity, Reliability and Quality as well as  reduction in lead time and cost . The skill level of technicians is continuously improved by Training Within Industry (TWI) programs.

TRAINING WITHIN INDUSTRY (TWI)

TWI is a proven methodology to convert capable and motivated workmen and supervisors into specialists in the respective areas of operation. The MRO Division is a young and fledgling family with challenges and opportunities. There is scarcity of skilled technicians with experience in various critical activities. It is required to capture the small yet key aspects of the activities in the systematic way and propagate it into workforce. TWI has been identified as a tool to standardize and propagate all the critical skill sets in the Division. 51 TWI events has been completed in 2008 and 50 more are identified for the year 09-10.

POLICY DEPLOYMENT MATRIX

The Policy Deployment Matrix approach has been instituted in the Division to align the Division’s focus towards customer support. Reduction in lead times, stabilisation of periodic servicing at bases and seamless shifting to dedicated premises have been identified as the policy drives for the year 09-10.

ERP SYSTEM

A Customized  IFS system  is being developed  for Enterprise Resource Planning Activities such as methodizing, Procurement,  Inventory Management, Finance   Accounting,   Scheduling, Labour Monitoring,  H/c utilization, Tooling, Quality, Maintenance & Human Resource.  Besides this, Customer Relation Module (CRM), Interactive Electronic Technical & Logistic System (IETLS) will be implemented as pilot project  in MRO Division

• FUTURE PROJECTS

                                                                       ALH  WSI                                                                         LCH

MRO facilities for

• ALH - Weapon System Integration (ALH-WSI)
• Light Combat Helicopter (LCH)
• Light Utility Helicopter (LUH)
• Indian Multi Role Helicopter (IMRH)
• Naval Rotary Unmanned Aerial Vehicle (NRUAV)

For further information, please contact :                                      

General Manager (Marketing)        

HELICOPTER MRO DIVISION                                                     Hindustan Aeronautics Limited

Hindustan Aeronautics Limited                                                     15/1, Cubbon Road,

Post Bag No.1796, Vimanapura Post,                                        Bangalore – 560 001, India

Bangalore – 560 017, India                                                             Tel : 91-080-2286 5197

Tel :91-80-22322002, 22316813                                                  Fax: 91-080-2286 7140

Fax:91-80-22314354                                                                     Website : www.hal-india.com

E-mail : gm.mro@hal-india.com                                                  

With  Our  Customers . . . . . All  The  Way