World- Class Engineering Solutions In Aerospace

Comprehensive Solutions

Infotech HAL Limited4th Floor 110 A&B Electronics City Bangalore – 560100

Core competence of Two , Unified to provide World – Class Engineering Solutions in Aerospace

A Joint Venture Public Limited Company

Comprehensive Solutions

Operational ExcellenceCustomer Intimacy

About Us

Incorporated on : 23rd August 2007Commenced Business : 23rd January 2008Share Capital : 28 crores

Change in relationship:Buyer-seller Purchase, technology transfer/licensed production

Design and developmentCoproduction, participation in manufacture

Partnership

to

Change in rules( DPP):Offset 30% -50% for sales over $65 million USD Emphasis on design, development and coproduction, participation in manufacture

Aerospace market:CII projection is from $155 Million now to 1Billion by 2010Nasscom- Booz Allen Hamilton projection is 3 billion by 2020 Goldman – Sachs projection is BRIC economy to overtake G6 by 2050

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The Environment

The Vision

Process Cost ScheduleQuality

To provide high quality and cost effective comprehensive engineering and supply solution for the global aerospace market spanning the entire product life cycle

Range of offerings

CustomerValue

CustomerRequirements

Concept Engineering

Product Engineering

Manufacturing Engineering

Testing & Validation

Production Engineering

After Market Services

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Structural analysis • Static Structures• Rotating structures• Rotor dynamics and loads• Case and externals• Linear & non-linear dynamic analysis• Rotor dynamics and engine loads• Development of Macros and ESW• FAA report writing

Design & Production Definition • Legacy Conversion• Reverse Engineering• Solid modeling• Project engineering support• Redesign for product improvement, cost

reduction, weight Reduction• Conceptual design of components

Thermal engineering • Compressor & Turbine Rotor Thermals• Compressor & Turbine Case Thermals• Test Data reduction ,data matching & analysis• Technology improvements & ESW updates

Aerodynamics• 2D & 3D CFD analysis • Code development• Benchmarking of commercial CFD codes• Validation of test results using CFD

The Services

Testing & Validation

Concept

EngineeringProduction Engineering

After Market Services

ManufacturingEngineering

Product Engineering 

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Performance & simulation • Engine System performance analysis• Field support • Test support & test report writing• Performance and simulation analysis• Code development for performance &

simulation

Control & Diagnostic Systems • Advanced diagnostic and engine

management• Field support • Test support• Engine health monitoring

Air & Oil systems design and Integration • 2D and 3D CFD analysis• Technology development and ESW update• Legacy & OCE engines modeling & SF analysis• Test support, Data reduction ,data matching &

analysis• SF analysis of advanced and developmental engines• Thermal managements systems• Nacelle and ventilation systems

CIPT & IPT • Multi disciplinary team proficiency• Standard work compliance• OCE corrective action programs• Rigorous root cause investigation

using field data • High fidelity analytical simulations

The Services

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Global Material Support capabilities• Reverse Engineering• Repair mapping and development• Salvage clinic• Patent search and mapping• Manufacturing planning, • Process planning• Tool design

Global Support Engg. capabilities• Airline support & cactus wires• Repair design and validation• Repair mapping & documentation• Airfoil repairs• Case and combustors• Rotating structures repair• Design Metallurgy support

Maintenance Data Service Engg. • CMM’s - New & Revisions• Repair writing• Service Bulletin Updates• Illustrated part catalogues• Conversion to electronic manuals

Manufacturing Engineering• Process Engineering & Reviews• Process Compliance and validation• Tooling services• Manufacturing program management• Special process quality checks• Quality assurance• Solumina Implementation support

The Services

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The Structures Team provides services for new product development, continuous product development and repairingprocesses to its clients. Some of the significant areas of support have been:

• Bladed rotor dynamics• Impact dynamics• Component lifing (LCF/ HCF)• Multidisciplinary Optimization• Methods and Tools Development.The team has competencies in all leading FEA tools like MSC / NASTRAN, ANSYS, ABAQUS, LS-Dyna,Pro / Mechanica, I-Sight, etc., and has been using these along with leading product design tools such as UG, Pro / Engineer and I-DEAS and CATIA for providing world-class support to its clients.

Aero Structures

Heat Transfer Expertise The team conducts thermal and CFD assessments for commercial and industrial engine components. The scope of heat transfer work includes development and validation and finite element models against actual test data and provides thermal analysis for durability assessment of components.

The Capability

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Aftermarket ServicesThe Aftermarket Services Group currently provides spares and repair and overhaul support to customers worldwide.

Engine service and overhaul centers are vital parts of the support chain and they rely heavily on Aerospace Engineering Capability. IHL with its trained and experienced engineers can support all 'airlines repair and overhaul' customers throughout the world. Our services are in the area of:

• Repair process development• Application engineering• Propulsion system analysis• Reverse engineering.

Aero-engines Repair Development engineers are trained to recommend specialized repairs for all engine hardware such as rotors, stators, externals, cases, mechanical components, casings, airfoil and combustors after studying the relevant documentation

The Capability

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Capability Matrix

6 Component Testing 60% Support

7 Engine Layout 30% Support

8 Structural Analysis 70% Lead

9

Rotor Dynamic analysis/vibration

analysis 50% Support

10Detailed Component

Design 60% Lead

11 LRU Design/matching 40% Support

12 Engine testing 80% Lead

13Redesign and analysis

- iterations 50% Support

14 Certification 60% Support

15 Documentation 70% Lead

16 TOT to manufacturing 30% Support

17Design of Tools, Jigs

Fixtures 40% Support

18 Turbine Engine Life Management 50% Support

19Air system design & Integration 30% Support

20 Engine Controls 20%  

- Engine valves    

- Electronic fuel controls    

- Mechanical fuel controls

- Heat exchangers    

- Air Turbine start systems    

- Active side stick    

- ETRAS( Electro Mechanical Thrust Reverser Actuation System)

Sl No Steps

DESIGN% of

contribution RoleSl

No Steps

DESIGN% of

contribution Role

1 Conceptual Design 30% Support - Constraint Analysis     - Mission Analysis    

- Propulsion requirement analysis

- Cycle Selections    

2 Component Design     - Fan/Compressor 30% Support

- Combustion Chamber 30% Support - Turbine LPT 20% Support - Turbine HPT 10% Support - Intake/nozzle 30% Support

3 Matching of Components 20% Support

4Cycle analysis: parametric & off design performance analysis 30% Support

5Component Pro-type Manufacture 10% Support

Sl No Steps

DESIGN% of

contribution Role

Focused Areas & Roles

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The Capability

High Low

Risks InvestmentsRegulatory Requirements

Product Engineering

Cost Advantage

After Market Services

Production Engineering

Testing & Validation

Manufacturing Engineering

Concept Engineering

Capability Maturity

Areas Risks InvestmentsRegulatory Requirements

Product Engineering

Cost Advantage

After Market Services

Production Engineering

Testing & Validation

Manufacturing Engineering

Concept Engineering

Capability Maturity

Areas

Opportunity Framework

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Our Credentials

Concept Engineering

Conceptual Design

Analysis

- Structural

- Thermal

- CFD

- Vibration

Optimization studies

Our Credentials

Product Engineering

Stress and vibration analysis

2-D and 3-D thermo-mechanical modelling and analysis

3D Modeling

2D Drafting

Geometric Dimension & Tolerances

Our Credentials

Manufacturing Engineering

Manufacturing Program Management

Manufacturing Process Planning

Tool Design

3D part planning

NC Programming

Vericut Simulation

Repair / Assy. Process planning

Our Credentials

Testing & Validation

Aero Engine Testing

Aero-Thermal Rig Testing

Aero-Acoustic Testing

Flow Testing

Component Testing

- Fatigue

- Vibration

Our Credentials

After Market Services

Technical publications

Repair design and advice

Service bulletins

Testing, performance analysis

Health monitoring and Reliability analysis

Fleet Management Program monitoring

After Market commercial support - Warranty

The Team

Performance Model

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Re- Design ( 30%) Manufacturing (18%)

102%101%100%99%98%97%96%95%94%93%92%91%90%89%88%87%86%85%84%83%82%81%80%79%78%77%76%75%74%73%72%71%70%69%68%67%66%65%64%63%62%61%60%59%58%57%56%55%54%53%52%51%50%49%48%47%46%45%44%43%42%41%40%39%38%37%36%35%34%33%32%31%30%29%28%27%26%25%24%23%22%21%20%19%18%17%16%15%14%13%12%11%10%9%8%7%6%5%4%3%2%1%0%-1%-2%

35

Comparision Global vs India Cost

47444138

59565350

32302724211815129630

Tooling (27%)

The Benefit

#######################################################################################################################################################################################################################################################################################9%8%7%6%5%4%3%2%1%0%-1%-2%

58

Graph on comparision of UK Cost & India Cost

77726762

96918682

5348433834292419141050

102%101%100%99%98%97%96%95%94%93%92%91%90%89%88%87%86%85%84%83%82%81%80%79%78%77%76%75%74%73%72%71%70%69%68%67%66%65%64%63%62%61%60%59%58%57%56%55%54%53%52%51%50%49%48%47%46%45%44%43%42%41%40%39%38%37%36%35%34%33%32%31%30%29%28%27%26%25%24%23%22%21%20%19%18%17%16%15%14%13%12%11%10%9%8%7%6%5%4%3%2%1%0%-1%-2%

211470

49423528

77706356

84

Comparision of Global Cost & Indian Cost

1121059891

140133126119

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22%Overall 22% savings

Knowledge Management – A Key Delivery Enabler

The Performance Enablers

ProductivityGainer

Support Communities

Assets Templates Coding

Standards and

Guidelines Reusable

Components

Best practices

Lesson Learnt

Technology Updates Current Events Cross CoE Interaction

Technology Sharing Cross Business Knowledge Sharing Challenging technologies Educational Sessions by

Premier Universities Professors

In House• Automation Tools• Jigs Fixtures

Training Classroom Training 75 + CBT Titles

G

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The Metrics

AnalyzeMeasure Improve ControlDefine

50

70

90

110

130

150

170

190

Dec-01 Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Nov-02 Dec-02

Effe

ctiv

ity %

Actual

Effectivity

50

60

70

80

90

100

Dec-01 Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Nov-02 Dec-02

On

Tim

e De

liver

y %

-30

-25

-20

-15

-10

-5

0

51 2 3 4 5 6 7 8 9 10 11 12 13

Days

Spa

n (+

Late

, - E

arly

)

On Time Delivery %Days Span (P95 - 5)

On-time Delivery

50

70

90

110

130

150

170

190

Dec-01 Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Nov-02 Dec-02

Effe

ctiv

ity %

Actual

Estimate Compliance

50

70

90

110

130

150

170

190

Dec-01 Jan-02 Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Nov-02 Dec-02

Effe

ctiv

ity %

Actual

Defects & Simulated Feedback

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Thank You!

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