By Vijay Grover
After facing initial headwinds and delays, Hindustan Aeronautics Limited (HAL) is making a determined push to ramp up production of the Tejas Light Combat Aircraft (LCA), a crucial component of the Indian Air Force’s (IAF) modernization efforts. With engine deliveries from GE expected to stabilize, HAL is streamlining its processes, optimizing its supply chain, and investing in infrastructure to accelerate the rollout of the indigenous fighter jet.
The Tejas, designed and developed by the Aeronautical Development Agency (ADA) and manufactured by HAL, is seen as a game-changer for the IAF, which has been grappling with a dwindling number of fighter squadrons. The aircraft’s indigenous design is a major boost for India’s self-reliance in defense production, a strategic priority for the nation.
However, the Tejas program has faced its share of challenges, primarily due to delays in the supply of engines from US-based GE. These delays created a bottleneck in HAL’s production line, impacting delivery schedules and raising concerns about the program’s timeline. After the issue was flagged by Air Chief Marshal Amar Preet Singh last year, HAL has taken up criticism in the right spirit by reworking strategies.
The Indian Air Force (IAF) has played a crucial role in supporting HAL right since the inception of India’s first indigenous Light Combat Aircraft. IT placed orders for the Tejas in a phased manner, reflecting the aircraft’s development and evolving requirements.
The IAF initially ordered 40 Tejas Mk1 aircraft, comprising 32 single-seat fighters and 8 twin-seat trainers. These aircraft are powered by the GE F404 engine and have achieved Initial Operational Clearance (IOC) and Final Operational Clearance (FOC).
In 2021, the IAF placed a significant order for 83 Tejas Mk1A aircraft. This advanced version features improved avionics, radar, electronic warfare capabilities, and a mid-air refueling system. This order is very crucial for addressing the IAF’s fighter squadron shortage and promises to make the Tejas the mainstay of the IAF’s capabilities.
The IAF is also planning to order 97 Tejas Mk2 aircraft. This variant will be a more capable fighter with a more powerful GE F414 engine, allowing for increased range, payload, and performance. The Tejas Mk2 is intended to replace older generation fighters in the IAF fleet.
Now, with GE promising revised delivery schedules starting in March, HAL is shifting into high gear. “We are working closely with our suppliers and partners to ensure a smooth and efficient production process,” said a senior HAL official, who wished to remain anonymous. “We have learned from the initial delays and are implementing measures to prevent similar issues in the future.”
Given the expectations of the nation, HAL has implemented lean manufacturing principles, a methodology focused on minimizing waste within manufacturing systems while simultaneously maximizing value for the end customer. This involves analyzing each step of the production process to identify and eliminate non-value-added activities, such as unnecessary movement of materials or redundant inspections. To further optimize its production lines and reduce turnaround time for each aircraft, HAL has invested in automation, introducing robotics and computer-controlled machinery to perform repetitive tasks with greater speed and precision. This has not only accelerated the assembly process but also improved the overall quality and consistency of the aircraft.
In addition to these technological advancements, HAL has also reorganized its production floor layout to facilitate a more efficient flow of materials and work-in-progress, reducing bottlenecks and optimizing the utilization of space and resources. These combined efforts have enabled HAL to significantly shorten the production cycle for each Tejas aircraft, allowing HAL to deliver more aircraft in a shorter period.
Supply Chain Optimization: HAL is working closely with its network of suppliers to ensure a consistent and timely flow of components. It is developing alternative sources for critical parts to mitigate the risk of future supply disruptions.
Infrastructure Development: HAL is investing in expanding its production facilities and upgrading existing infrastructure to accommodate the increased production rate. This includes new assembly lines, testing facilities, and hangars.
Skilled Workforce: HAL says it is also focusing on training and upskilling its workforce to ensure they have the expertise to handle the complexities of Tejas production.
With Tejas becoming a hallmark product of Prime Minister Narendra Modi’s Make In India initiatives, officials at HAL concur that their commitment to the Tejas program goes beyond simply assembling the aircraft. They share that their teams are deeply involved in the integration of the GE engines, ensuring seamless operation and performance. Importantly, to build confidence, HAL says it is responsible for providing long-term maintenance, repair, and overhaul (MRO) support for the Tejas fleet, ensuring its operational readiness for decades to come.
The Tejas is not just another aircraft for the IAF and India, it represents India’s growing capabilities in defense manufacturing. HAL’s role in bringing this indigenous fighter jet to fruition is paramount. Despite the initial setbacks, HAL has demonstrated its resilience and commitment to the program. As engine supplies stabilize and production ramps up, the Tejas is poised to become a mainstay of the IAF.
A full fleet will go a long way in bolstering India’s air power and cementing HAL’s position as the backbone of aircraft production for the Indian armed forces, especially when it comes to the crucial Tejas program. The success of the Tejas is inextricably linked to HAL’s capabilities, and the nation’s security rests, in part, on the shoulders of HAL.
The renewed focus and dedication at HAL signal a positive trajectory for the Tejas program, reinforcing its crucial role in safeguarding the nation’s skies.
Vijay Grover is the Editor of Indian Aerospace & Defence
