MRO

Feature by Aeroclass Ever since the start of the pandemic, the MRO (Maintenance, Repair, and Overhaul) industry has faced many challenges that had an impact on many industry players. According to Anca Gosling, Director of Training Content and Development at Aeroclass, an aviation digital learning platform, despite hurdles, the industry is expected to reach new heights in the coming years. The current state of the MRO market indicates a remarkable recovery, with a projected market value of $94 billion in 2023, an increase of over 20% from the previous year. This growth signifies a return to pre-pandemic levels, as the global fleet has recovered by 98%, and passenger traffic has reached 90% by the beginning of 2023. However, Gosling points out that amidst this positive outlook, the industry further continues to face challenges that impede its rapid development. One of these challenges is effective labour and material cost management as material costs are expected to experience inflation of approximately 6.7% annually over the next couple of years. Gosling explains that to counteract this, MROs are focusing on increasing the usage of used serviceable material (USM). With retiring current-generation fleets, there is ample opportunity to salvage materials, while the commonality between current and next-generation fleets facilitates USM adoption. Shortage of qualified staff Another significant challenge lies in the shortage of qualified staff, particularly maintenance technicians. Anca Gosling explains, “As demand for MRO services rebounds, the industry has had to rapidly scale up production and maintenance operations with fewer employees. To address this issue, operators are implementing measures such as educational outreach, subsidized technical training, improving the work environment, recruiting talent from other industries, and utilising internet-based recruitment platforms Online training and courses, such as the ones offered by Aeroclass, can also play a vital role in optimizing staff training and onboarding processes, enabling faster and more streamlined training programs.” Additionally, the MRO industry faces challenges in its material supply chain. Original Equipment Manufacturers (OEMs) and suppliers have struggled to meet the increased demand for parts, leading companies to rely heavily on the aftermarket for supplies. “This strain on the supply chain highlights the need for improved collaboration and coordination between OEMs, suppliers, and MROs to ensure efficient and timely availability of required materials,” she shares. Address challenges amicably While the MRO industry is poised for recovery and growth, several challenges must be addressed to ensure its sustained success. Effective labour and material cost management, tackling the shortage of qualified staff, and overcoming material supply chain disruptions are all critical areas that require attention. By implementing strategic solutions such as increased usage of USM, investing in training programs and online education, and collaborating closely with suppliers, the MRO industry can navigate these challenges and continue its upward trajectory, driving innovation and efficiency in the aviation sector. (Aeroclass is the first digital learning platform to focus specifically on the aviation market.Aeroclass is part of the Avia Solutions Group family, the world’s largest ACMI (Aircraft, Crew, Maintenance, and Insurance) provider, with a fleet of 180 aircraft, and a parent company of SmartLynx, Avion Express, Bluebird Nordic, BBN Indonesia Airlines, KlasJet, Magma Aviation and more.)

Paris Air Show, 22.06.2023: GKN Aerospace announced the first delivery of F-35 Lightning II wheels and brakes assemblies serviced and maintained at its GKN Fokker landing gear facility in The Netherlands. This delivery marks the first shipset of its contract to service and maintain wheels, brakes and strut assemblies for the F-35 fleet in Europe. Shawn Black, President of GKN Aerospace Defence Business said: ”This is a tremendous step in expanding the F-35 industrial base while shortening maintenance times in Europe and increasing international partnership in the program. We look forward to continuing our work with Lockheed Martin in supporting this vital multi-role fighter in Europe and the Pacific.” GKN Aerospace’s Fokker business received the contract award to maintain and service the F-35 landing gear from the Joint Program Office due to its extensive experience in landing gear maintenance, repair and overhaul (MRO) in other platforms including the F-16 and the NH-90 helicopter. Along with maintenance activities, the landing gear business is also involved in the design and manufacturing of the F-35 arresting gear and the development of the F-35 composite landing gear drag brace. GKN Aerospace has been involved in the F-35 program since the start and has designed and manufactured electrical wiring interconnected systems, flaperons, in-flight opening doors, cockpit canopy, air frame parts and arresting gear for all F-35 aircraft.

Bangalore. 6th Feb 2023: Prime Minister Narendra Modi dedicated to the nation Hindustan Aeronautics Limited (HAL) Helicopter Factory at Tumakuru in Karnataka on February 06, 2023. He took a walk through of the Helicopter Facility & Structure Hangar and unveiled the Light Utility Helicopter (LUH). The factory is India’s largest helicopter manufacturing facility and will initially produce LUHs. The LUH is an indigenously designed and developed three-ton class, single engine multipurpose utility helicopter with unique features of high manoeuvrability. Initially, this factory will produce around 30 helicopters per year and can be enhanced to 60 and then 90 per year in a phased manner. Addressing the gathering, the Prime Minister said, Karnataka is a land of saints and sages that have always strengthened the Indian traditions of spirituality, knowledge and scientific values. He lauded the talent and innovation of Karnataka’s youth and said the manufacturing sector’s strength is manifested in products from drones to Tejas fighter planes. “Double-engine government has made Karnataka the first choice of investors,” the Prime Minister asserted and illustrated the point by the HAL project dedicated today, for which he had laid the foundation stone in 2016 with a pledge for reducing foreign dependence for defence needs. The Prime Minister expressed delight that hundreds of arms and defence equipment are being manufactured in India which are being used by the Armed Forces. “From advanced assault rifles to tanks, aircraft carriers, helicopters, fighter jets, transport aircraft, India is manufacturing it all”, the Prime Minister remarked. Throwing light on the aerospace sector, the Prime Minister pointed out that the investment made in this sector in the last 8-9 years is five times the investment made before 2014 plus 15 years prior. The Prime Minister underlined that Made in India arms are not just supplied to the armed forces but the defence exports have also grown manifold when compared to the years before 2014. He emphasised that hundreds of helicopters are going to be manufactured in this facility itself in the near future which will give rise to businesses worth Rs four lakh crore. “When such manufacturing units are set up, it does not just strengthen the Armed Forces but also creates employment and self-employment opportunities,” Shri Modi remarked as he underlined that small businesses near the helicopter manufacturing facility in Tumkuru will get empowered. The Prime Minister emphasised that with the spirit of ‘Nation First’ success is assured. He talked about revamping and reforms in the working of the public sector enterprises as well as opening up opportunities for the private sector. The Prime Minister referred to the recent propaganda to target the government in the name of HAL and said that falsehood, no matter how big, frequent or high, is always defeated in the face of truth. “This factory and the rising strength of HAL has exposed the purveyors of falsehood. Reality is speaking for itself,” he said and added that today the same HAL is making modern Tejas for the Armed forces and is a centre of global attraction and bolstering India’s ‘Aatmanirbharta’ in the defence sector. In his address, the Raksha Mantri lauded the Prime Minister’s visionary leadership, saying that it has fuelled the rise of a ‘New India’ which has the ability to illuminate the world with its light. He stated that India has been a major centre for production and export of silk, cotton & steel and it has now embarked on a journey to become a global hub in manufacturing, especially in the field of defence. He described the HAL Helicopter Factory as a testament to the country’s growing indigenous capabilities and the Government’s unwavering resolve to achieve ‘Aatmanirbharta’ in defence manufacturing. Shri Rajnath Singh also called the inauguration as a tribute to the innumerable heroes and freedom fighters of Karnataka who sacrificed their lives to protect the nation. He added that the facility is a reflection of the Swadeshi movement inspired by leaders like Father of the Nation Mahatma Gandhi. “The Swadeshi movement, which started a century ago, was the first phase of our independence. That was National Movement 1.0. Our vision of ‘Aatmanirbhar Bharat’ is the second phase. It is National Movement 2.0, through which we are moving fast towards freedom from foreign equipment,” he said. The Raksha Mantri stressed that under the Prime Minister’s leadership, the Armed Forces have marched ahead in the defence of the nation with renewed vigour and enthusiasm. Not just the soldiers, but scientists, engineers, machinists, technicians, MSMEs, individual innovators, start-ups, industrial workers and all other sections are contributing to national security and socio-economic empowerment of the country, he added. Shri Rajnath Singh stated that while the Armed Forces are at the borders, every citizen is behind the scene supporting and encouraging them. The HAL Helicopter Facility is a proof of that collective resolve, he said. About HAL Helicopter Factory The Greenfield Helicopter Factory, spread across 615 acres of land, is planned with a vision to become a one-stop solution for all helicopter requirements of the country. After initially producing LUHs, the factory will be augmented to produce other helicopters such as Light Combat Helicopters (LCHs) and Indian Multirole Helicopters (IMRHs). It will also be used for Maintenance, Repair and Overhaul of LCH, LUH, Civil Advanced Light Helicopter (ALH) and IMRH in the future. Potential exports of civil LUH will also be catered to from this factory. The HAL plans to produce more than 1,000 helicopters in the range of 3-15 tonnes, with a total business of over Rs four lakh crores over a period of 20 years. Besides generating direct and indirect employment, the Tumakuru facility will boost the development of surrounding areas through its CSR activities with large-scale community centric programmes on which the company will spend substantial amounts. All this will result in improvement in the people’s lives in the region. The proximity of the factory, with the existing HAL facilities in Bengaluru, will boost the aerospace manufacturing ecosystem in the region and support skill & infrastructure development such as schools,

At the Aero MRO A&D 2022 conclave, it was on opportunity to meet Anil Kumar Kapoor, Executive Director( Engg), AIESL .We discussed on various keys issues pertinent to AIESL vision, govt policy, scope ahead for Indian MRO , disinvestment etc. Excerpts from the interaction… Vishal Kashyap, Managing Editor, Aviation World What are the priorities areas that you are seeking for MRO sector on behalf of AIESL for 2023? We are looking for the potential segment of base maintenance, engine MRO and component facility which already exists with AIESL. We want to penetrate deep into international markets and perhaps as of now only 5-8 % share is within India and rest all is going as import to OEMS & manufacturers. So, we definitely like to retain this share outgo within India and with government thrust on ‘Make in India’ and ‘Atmanirbhar Bharat’ we look forward to retain business In-house and perhaps in keys areas, we are announcing our capabilities, capacities to match anticipated work load. As India will be emerging as a 3rd largest aviation market in the world, so MRO sector is also bound to grow by leaps & bounds. To cater to these requirements, definitely we are upgrading our skill set, increasing our man power, penetrating deep into the market segments, getting more clients on board l. We are perhaps getting a new customer in the shape of defence sector. We have jointly signed many agreements; MoU with regard to DRDO , IAF and some mission aircrafts also to cater to their specific needs, base maintenance, C -Checks , D- Checks , structure repair, modifications, etc. How India will be able to retain MRO business within India, which seems to be potential challenge as of now? You rightly pointed out that majority chunk is going out of India as imports, be it OEMs support, spare support, and the proprietary rights which OEMS and manufacturers are not ready to share with other competitors. We need to have collaborations with bigger players and different OEMS to come down to India and have JVs and joint working groups or some MoUs need to be signed on dotted lines so as to improve infrastructure and give a manufacturing boost within India so as to at the same time will be catering to Make in India and Atmanirbhar drive and save foreign currency outgo and generate lot of employment. These are potential segments and can’t be imagined the inflow of new orders of aircrafts, defence aircrafts. So, we need to have JV and share the skill set with OEMS and perhaps give them lucrative offer in our various locations to set up their manufacturing hubs there. And, perhaps from here we can export to different part of the world. What’s your take on the taxation part, which has always been red flagged by the MRO industry? There are lot of things that have been done by the Civil Aviation ministry and Govt. of India. Earlier, the taxation policies were very high and recently, few months back it has been reduced which makes us more competitive when we compare with Malaysia and other Asian counterpart’s because there the taxation policies are as good as negligible. But, presently in India also its almost 5 % which is not much . Apart from that some customs relaxations with regard to procurement of spares and if further something down with taxation can be done, it will further announce MRO activities and boost will be given to this industry. What are the issues which need to be resolved to avoid safety challenges of our aircrafts? There are definitely some issues which have come to light in the recent past. There are few cases with engines related to maintenance and quality compromises or some known glitches which vendor also acknowledges by airlines. Although parallel maintenance activities to counter such incidents are already being initiated by airlines. But, still few incidents keep on happening, at the same time the manufacturers are also taking corrective steps to stop such incidents. They do lot of investigation and research putting lot of efforts to avoid reoccurrence. Our regulator DGCA had its own audits program, spot checks and they are very careful on such issues. Is disinvestment still a long way process for AIESL? No, it should not be a long way process as DIPAM secretary, MoCA, is all geared up and we ourselves have given all data to our advisors who are taking it forward. May be by this year end all documents should be ready and global tender should be floated out. So, whosoever is the contender, with the highest bid will take over AIESL. We expect it to be selling within this FY itself hopefully, keeping all finger crossed.

AW Feature Why do aircraft need effective Radome protection? In this feature the writer has dwelled upon one of the key elements of aircraft equipment that need to be protected in a very economical and effective solution. By Abhik Pal Radomes are usually large dome-shaped structures, often made up of composite, which protect the radars against rain, sand erosion and particle impact with minimal impact to attenuation of electromagnetic signals being received by the radar. However, being a composite material, they are prone to various types of damages including erosion caused by Foreign Object Debris (FOD) such as rain and sand while flying at speeds of 200-500 mph under demanding weather conditions. Once damaged, radomes need to be removed, assessed, and repaired / replaced. Radomes are high value assets (one A320 Radome costs approx. $80,000 to replace with subsequent downtime involved with repair/ replacing the radome). It is observed that sometimes airlines use a white coating on the damaged portion of the radome as a quick fix. However it is not a fool proof solution as the level of erosion protection offered by paints/coatings is not adequate and specialized equipment is typically required to refinish radomes per the C.M.M., (Component Maintenance Manual) making the coating repair process expensive and time consuming. Therefore, it is desired to have economical and effective solutions available to protect those high value assets that are subject to damage. Polyurethane tapes with adhesive backing provides several advantages over coatings e.g. uniform thickness / weight, no specialized tools are needed for installation, easily repairable with patch tape and repair paste, easily removed if needed, long service life etc. Refer Fig 1 for a representative comparison between coatings and a polyurethane tape (3M™ Polyurethane Protective Tape 8673) during a rain erosion test. Radome Boot: A Radome “boot” is sheet of protective tape thermoformed into the same, curved shape of the radome and is preferred over flat tape which can be difficult to install over curved surfaces. Typical Benefits of Polyurethane Radome Boots: • Radome boots are typically made of an abrasion-resistant polyurethane and are resistant to ultraviolet light. The product is constructed with a durable, solvent-resistant, pressure-sensitive acrylic adhesive, and protected with an easy-release liner. • Radome boots provide excellent erosion protection for aircraft, from radomes to navigation light lenses and help keep these vulnerable components looking good between heavy maintenance intervals. • They are usually available in a variety of shapes and colors for many industrial and common aircraft applications (including radomes, wing tips, landing gear pods, etc.) • Typically, they are transparent, paintable and can be applied over painted surfaces and forms a protective barrier between vulnerable surfaces and damaging elements. • Radome boots do not significantly interfere with radar transmissivity. For aircraft radomes, their optimized thickness is virtually invisible to radar. • They are extremely simple and easy to install. Once installed, they establish an excellent erosion barrier. • Radome boots prevent paint and surface erosion, even on the most vulnerable leading surfaces of the aircraft such as radomes, wing tips, wing root fairings, horizontal stabilizer tips, tail fairings, spinners, landing gear components and more. Protective boots provide many years of paint erosion protection, making them a cost-effective aircraft paint and surface protection solution. (The writer is Technical Lead – Aerospace at Automotive and Aerospace Solutions Division of 3M India Ltd.)

The commercial aviation sector is beginning to stretch its wings once again as international travel resumes. This revival has spotlighted a number of pinch points to be dealt with—such as reintroducing stored aircraft and converting passenger planes to cargo configurations and back again, all while balancing remote working and financial overheads to secure a long-term period of renewed growth and profitability.Technology is providing the answers. As OEMs, airlines, and MROs focus on integrating new technologies into their value chains and embracing digital transformation, we look at three key areas where new advancements can be most valuable and easily integrated to help gain competitive advantages in a sector where there is a fine line between profit and loss. Rob Mather, Vice President Aerospace & Defence Industries, IFS, explains. Since 2020 the aviation industry has faced unprecedented change, instability, and shock which has rippled throughout the entire sector—from flight restrictions and a host of quarantine regulations to complete state-wide commercial shutdowns that OEMs, airlines and MROs are still recovering from. Cancelled flights, mothballed planes, and aviation uncertainty Initial pandemic pressures saw onsite work change drastically. New restrictions, staff shortages due to isolation and stringent social distancing restrictions have all been challenges for businesses. In some cases, this has opened new opportunities for companies who have unlocked the potential—examples are the boom in freight and the corresponding uptick in ‘preighters’, the conversion of aircraft from passenger to cargo configuration, and the FAA using remote working channels in the evolution of the 737-MAX. There has also been a mixed reaction in reducing fleet sizes. Cirium reported that large commercial jets saw a 15% decrease in retirements as replacement orders became uneconomical—this was as OEMs were hit by worker and supply shortages. For example,the EU Parliament found European demand for manufacturing decreased by 43% in 2020 primarily due to Airbus order deferrals. Other airlines accelerated the retirement of costly aircraft with Oliver Wyman’s data showing 5,000 aircraft that were in service at the start of 2020 were no longer flying at the beginning of 2021. However, recovery has begun as passengers once more take to the skies with a predicted 47% more passengers flying in 2022 than in 2021—aided by increased vaccination numbers and lower Covid infection rates. This recovery is projected to only strengthen through the rest of this decade as worldwide fleet numbers are due to increase to 36,500 by 2031. This recovery is not without its unforeseen challenges. The airport infrastructure has significantly hampered travel experiences for both airlines and frustrated passengers. Staff shortages created by pandemic-induced layoffs have not return to the same levels and the results have led to flight cancellations and extreme delays at airports globally. Technology is on course to deliver transformation But there is still opportunity for airlines who invest in future-proofing operations through digital transformation to be first off the runway—currently, only 10% of the top carriers have invested in technology initiatives such as predictive maintenance—which would give them a large competitive advantage in the next few years, and minimise delays caused by aircraft issues. Traditionally airlines run on very fine margins, meaning an airline’s value chain is as lean as possible, and as such the adoption of a major IT infrastructure project has traditionally been seen as a potential operational and financial risk. The industry as a whole typically has no slack that can be used for resource investment, and any threat of a disruption to normal service caused by an IT project can be very costly. But the pandemic changed all that. The technologies that are enabling aviation to taxi for take-off However, this increase in IT spending does not have to be dedicated to large-scale or business-wide overhauls. IFS has found that both MROs and airlines are benefitting from tools that can open transformative new areas of potential such as investing in predictive maintenance and the efficiencies it offers. There are several operational areas that will allow for a competitive advantage to be created or maintained in this new aviation reality of post-pandemic recovery and the continued threat of potential disruption. In particular, there are three key maintenance-focused technologies that can create this advantage throughout an aircraft’s life cycle. 1. Predictive maintenance redefines efficiency with AI and an IoT One of the maturing industry technology applications is the use of the Internet of Things (IoT) and Machine Learning (ML) for predictive maintenance. Maintenance software applications now allow for the aggregation of real-time sensor data, business & operations data, logs, and more into a data lake infrastructure—with the ability to transform all this information into proactive maintenance tasks. These data insights, along with machine learning models, can then be used to produce advanced statistics and KPIs to provide a holistic view of the asset or component in question, combining historical and forecasted values. Thanks to these digital developments, the often risk-averse aviation industry can pivot to using predictive maintenance models not only to increase performance and reduce costs but also to better manage risk and enhance safety. For example, as of 2020, Rolls-Royce is using AI forecasting, which is supported by IFS, to help airline customers automatically update predicted maintenance deadlines for every life-limited component inside their engines—a key part of the Rolls-Royce Blue Data Thread strategy, a digital information thread connecting every Rolls-Royce powered aircraft, every airline operation, every maintenance shop, and every factory. 2. Digital help stems from remote assistance Passengers will now be greeted by more mobile, touchless, and socially distanced technology to help navigate them through the airports. Similarly, airlines have deployed technology to protect their employees and deliver new operational efficiencies. The proliferation of smart devices, and maintenance software applications now available on mobile has fast-forwarded merged reality—where the real and virtual world are mixed and objects from both can interact. With remote working and social distancing becoming commonplace, remote assistance technology is ready and available and has been taken up by more and more airlines and MROs who are quick to see the benefits and adopt the

Châteauroux – 22nd February 2022: Vallair, the multi-faceted aviation business dedicated to the support of airlines and lessors, has opened the doors to its unique new maintenance hangar located at Marcel Dassault Airport in Châteauroux, France. The enormous state-of-the-art facility can accommodate up to five A321 size aircraft simultaneously, or a combination of A330/A340 and A321s. Together with the Centre-Val de Loire Region and the Châteauroux Centre Airport Establishment, Vallair is proud to play a key role in the reindustrialisation of France and its aeronautical scene with this A380 capable, 8,520m² hangar which will create nearly 200 jobs in the region.As this unique facility stands as one of the largest hangars of its kind in the world, this milestone has involved unprecedented collaboration from several parties. Supply chain shortages and COVID aside, establishing the infrastructure, resources and technology for this environmentally friendly facility has necessitated the resolution of many challenges. Grégoire Lebigot, Founder & CEO of Vallair, sums up what it means for local economy dynamics: “We are part of ‘Aérocentre’, the regional centre of excellence in Centre-Val de Loire that works to develop and sustain the aeronautical sector across the area with over 120 member organisations. Vallair stands as one of its key players over the last fifteen years and we are proud to be part of the rich aviation heritage in the heart of France.” “During this period, we have developed an unparalleled expertise in the aerostructures arena, including composites and key components like nacelles and thrust reversers on site, along with aircraft recycling, cargo conversions, and our MRO activities which now extend to widebody capabilities. It is our aim to ensure that our customers can benefit from all these complementary on-site skills and the associated cost savings that we can offer.” Parking and storage at CHR airport can already accommodate widebodies and Vallair believes this is the perfect timing and opportunity to enhance its capabilities and reach those airlines who are presently struggling with maintenance slots. Vallair will initially focus on Airbus A330 heavy maintenance capabilities with a view to adding A340, A350, and possibly Boeing B777 capabilities in the near future. In-house cargo conversion services will also commence with narrowbodies and quickly expand to a range of other popular platforms, including widebodies. Lebigot adds further details about the Company’s objectives. “We’re excited to build up a new reputation for widebody excellence as we enter into 2022, this is the dawn of a new era for Vallair and our customers. Our activities in Châteauroux will also focus on passenger-to-freighter conversions and a dedicated unit will showcase our significant experience and knowledge in this area. As we step up our P2F programme it is essential for us to expand our resources across all geographical areas, and we will now be able to efficiently re-locate several conversion projects to France. In addition, our expertise with mature aeronautical assets enables us to follow our sustainability agenda as Vallair continues to grow.” Lebigot goes on to say, “Since mid-2020, the project has been an incredible journey and a major investment. Everyone involved has been committed to reach the ambitious deadlines and everyone in the Vallair team must be congratulated for their dedication and unstoppable enthusiasm. I’d also like to thank François Bonneau, President of Region Centre Val de Loire, Dominique Roullet, President of Châteauroux Airport, and their teams, for their continuous support.” “This new extension of Vallair’s services in Châteauroux will operate alongside our existing narrowbody MRO and painting capabilities in Montpellier” continues Lebigot. “We are part of the Aerospace Valley, a French cluster of more than 800 aerospace and engineering companies and research centres located in the regions of Occitanie and Nouvelle-Aquitaine in the southwest of France. “The aviation industry has faced an unprecedented a time of turmoil over the past two years, but recovery is evident. Vallair’s expanded capabilities in France will offer both operators and lessors a comprehensive solution whilst improving efficiency and turn-around times.”

Dubai,22nd Feb 2022: At MRO Middle East, Satair, an Airbus Services company and Joramco, an independent commercial aircraft maintenance, repair and overhaul company, extended an agreement covering the supply of consumables and expendables for the support of Boeing and Airbus aircraft.The contract secures solid regional spares availabilities for Joramco and brings the benefits of costs savings, relieving the supply chain and minimizing the risk of AOGs. With a history of doing business together for more than 25 years, the deal further strengthens the partnership between Satair and Joramco. The agreement has global coverage and is set to go into effect from 22 February 2022. Fraser Currie, Joramco’s Chief Executive Officer stated: “We are delighted to extend our long-term cooperation with Satair who will continue to be a reliable partner in our sourcing and procurement activities by ensuring and sustaining our access to parts and reducing our lead times.” Terry Stone, Satair’s Managing Director and Head of Sales and Support, EMEA, added: “This is an important step in further developing our support to MROs in the Middle East and to increase material availability for our long-trusted partner.”