A newsletter From Godrej Aerospace
Market Insight Rebound post pandemic Focus 100,000th Aero Engine Bracket to Rolls-Royce delivered Industry Achievements Enhancing in-house competence for qualifying the quality standards
Industry Achievements Delivery of landmark 200th set of BrahMos airframe assemblies Employee Connect A glimpse of employees engagement programs...
OCT - DEC 2021
PARTNERING IN SELF-RELIANT PROGRAMS OF INDIA S.M. VAIDYA
Executive Vice President & Business Head, Godrej Aerospace
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reetings for the season!! We just finished first half of this financial year and exceeded our business plan for the first time in last 20 years. Big thanks to Integrated missile manufacturing LOB who stepped up production and consistently delivered 4 systems in all the 6 months. Exports team also exceeded plan owing to some signs of opening of Civil Aviation market. Whereas space and R&C LOBs are putting optimum efforts to stabilize production and meet the Overall Business Plan. In nutshell, our forecast for H2 is strong and we will surely keep the lead achieved in H1 and maintain it in H2 also. BrahMos has further shown confidence in us by placing another order of 25 sets and why not when we delivered 200th assembly in the month of Oct 2021. Successful qualification of BrahMos booster by DRDL will now open one more assembly for us to participate. Space segment announced reforms and after Atmanirbhar Bharat in defence, we need to start planning and obtain approvals as we did with MoD. Sign of ramping up of production by Airbus and Boeing, Aero engine and other aggregate manufactures indicate 2022-23 would be far better than previous pandemic years. Happy to put in records that we completed first phase of capability building in BTS domain and has been cleared by DRDO- TDF committee. We are now marching ahead with Protos for type qualifications. With successful completion of phase 3 of Dalia actuators and final approval at sight, 100% import substitution thus Self-Reliance is visible in primary actuators for present and future generation fighter Jet and commercial aircrafts. Our business excellence assessment is completed successfully. It was a good learning sharing experience from Assessment team which will help to sustain our journey on business excellence from manufacturing excellence. We need to relook into our journey with TPM, TOC, Takaosan (consultant’s suggestions), IoT, automation and innovative approach in tooling. This will help in ramping up production and creating capacity for Atmanirbhar Bharat- Kaveri engine, actuators, complex sheet metal and opening of space program to private industry. It will lead to business growth without additional infrastructure and fixed cost reduction. With this, I am confident that that we are on right path of accelerating our business growth from SBP through Atmanirbhar projects and space opportunities. Wish you all a very safe, healthy and prosperous new year 2022.
Creating capacity for Atmanirbhar Bharat through TPM, TOC, IoT and Innovative approach
hightlight 2021
100,000th
AERO ENGINE BRACKET TO ROLLS-ROYCE DELIVERED
Godrej Aerospace executed the biggest order for an overseas customer
VINOD B. BHOSLE
Head- Export Fabrication LOB & SPD
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n 29th August 2016, we received a prestigious order from Rolls-Royce for T7000 Aero engine 198 brackets (project-Kingfisher) to be developed. It was further amended with 333 more brackets on 20th March 2018 for TRENT-XWB Aero engine (ProjectKite). The total contract value was $ 58,00,000 for 5 years. This was the biggest order from foreign customer. There were many challenges in executing the project, like, sourcing raw material from European approved sources, complex forming of Inconel-718 material with close tolerances, warm forming of titanium, controlling welding distortion, radiography weld joints with stringent acceptance criteria, intricate
riveting, additional qualification required for heat treatment & surface treatment and productionizing large variety of Brackets to maintain committed dispatches. We had developed Press Brake data bank for around 1200 parts forming. Technique sheets developed for radiography & Fluorescent Dye penetrant test Inspection (FPI). Laser substantiation carried out for heat affected zone within 0.05 mm up to 3.2mm thick sheets cutting. Around 40 welding fixtures & 24 standard & 15 special Press Brake tools are made. The FAIR & production journey started in March 2018 & successfully productionized 158 Brackets in FY17-18, 298 Brackets in FY18-19, 52 brackets in FY19-20 & balance 23 brackets in FY20-21.
How we did it
We are the only Indian supplier to qualify for Rolls-Royce radiography weld joint. Our quality & delivery scorecard is 100% since August 2020
Lot of improvements were done in manufacturing such as semi-automatic TIG welding by use of servo-controlled manipulator, butt welding without end run-in & run-out pieces, press brake bending without integral tabs, use of specially made Rolla-V die for 3mm flange bending without extra flange height, digital part marking template, 3D printed maskant for quick masking during painting, etc. Some of the improvements in Quality are, use of “Q-Pulse” FAI software for quick net inspect FAIR preparation, continued process capability study using “Minitab” for bend angle and bend length, use of functional gauges, APQP approach resulted in smooth NPI process and sustainable production process. Our efforts are well recognized by the customer. The Rolls-Royce, India Sourcing Head - Mr. Vijay Aralikatti visited our plant on 4th December 2019 & appreciated workmen for successfully developing & delivering radiography weld joint Brackets. We are the only Indian supplier to qualify for Rolls-Royce radiography weld joint. Our quality & delivery scorecard is 100% since August 2020. Within this successful journey, one more feather in the cap is added on 23rd September 2021 by handing over 100,000th bracket to Mr. Manikanta Kumar, Asia Pacific sourcing Manager of Incora, who manages Rolls-Royce global supply chain.
Handing over of 100,000th Bracket to Mr. Manikanta Kumar, Asia Pacific Sourcing Manager of Incora
Market Insight
6 REBOUND POST PANDEMIC Aircraft production and Make In India programs of India picks up
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PAURUSH BHESANIA
Marketing Head
t’s difficult to overstate the impact of the COVID-19 pandemic on the commercial aviation industry. Aircraft delivery deferrals and cancellations are happening at unforeseen levels. Over 1,000 narrow-body aircraft and 350 wide-body aircraft deliveries planned for 2021-2022 have either been pushed back or cancelled since the beginning of COVID-19. However, aircraft production is resuming, albeit slowly. There is evidence that production capacity is increasing atleast for the narrow-body aircrafts. Boeing 737 max has resumed production and received new order from United Airlines for 25 new 737 MAX aircraft for delivery in 2023. .Airbus production rates are expected to be less than 10% for narrow body aircraft from pre-covid levels. GE Aviation held a broadcast with all their suppliers regarding increase in production rates for leap engines. Safran has sent a letter to their suppliers talking about a new rampup and have urged suppliers to start planning for the capacity according to the ramp up. Honeywell has indicated that there is a V-shaped recovery seen in some of the parts.
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Rolls-Royce has indicated increase in flying hours of all their engines especially for business aviation. Recently, Godrej Aerospace also achieved a new milestone by signing our first long-term contract (10 years) with IAI, Israel for the manufacture and supply of tubing’s for Gulfstream business jets. Support from our partners M/s. ISOP in Israel was important to achieve this feat. For Rafael our orders are currently impacted due to the world focusing on spending on Covid and hence their restrictions on defence spending globally. As a result, Rafael is waiting for firm orders before they can commit to release more orders on us. On the domestic aerospace and defence sector, further to the announcement of ban on imports for 101 defence equipments by MoD in August 2020, MOD released the 2nd positive list of 108 defence equipment to be indigenously manufactured in May 2021. These policy initiatives have increased opportunities for Indian private industry participation in Aerospace and Defence sectors. Another significant development for “Make in India” initiative was the Government’s approval of procurement request for 56 Airbus C295 military transport aircraft for replacement of the legacy AVRO fleet of the Indian Air Force. Of the 56 aircraft on order, 40 aircrafts are to be wholly manufactured in India by TATA Advanced System Limited (TASL), the industrial partner of Airbus for this requirement. With the placement of MOD order for 83 Tejas fighter aircrafts on HAL, announcement of DRDO list of 108 technologies to be developed by private industry and the opening of Indian Space program for private industry participation in the previous financial year, the opportunities for private industry participation in the defence and aerospace sector has seen impressive growth. We are exploring, engaging and participating on new opportunities for aircraft engine, LRUs and composites.
Industry Achievements
SPECIAL PROCESS QUALIFICATIONS
Enhancing In-House competence for qualifying the quality standards
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n Aerospace environment, qualifications of personnel working in special process area is essential to perform the activities in accordance with standards and contracts. We were dependent on the external consultants for the NAS410 level 3 certification in NDT and source certifying agent in welding to fulfil the contractual requirements of export customers. To become self-reliant, internal team members were identified for qualifying the SCA and NAS410 level 3 certification examinations. These exams are conducted by independent authorities like performance review Institute (PRI) for SCA and UK NANDT board for NAS410 level 3 certification.
ROHIT DIWEDI
has passed the examination for Source Certifying Agent from PRI for Fusion Welding Planner by fulfilling the requirements of Honeywell customer.
SWAPNIL PATIL
is qualified for Non-Destructive Testing level 3 examination as per NAS410 standards in Magnetic Particle Testing. Balance methods like fluorescent penetrant inspection, radiography testing and ultrasonic testing are also planned to have internal NAS410 level 3 availability in the division. These qualifications will help to build the customer confidence on process adherence due to presence and surveillance of internal certified personnel.
TEAM SUDARSHAN WINS CII AWARD IN SUPERVISOR CATEGORY CII had organised “2nd CII Kaizen competition 2021” for manufacturing & service Sector on 26 August 2021. Team Sudarshan bagged 2nd Runner Up in Supervisor category Kaizen Theme: To reduce CCPM time for 100CB
DELIVERY OF LANDMARK 200TH SET OF BRAHMOS AIRFRAME ASSEMBLIES
Godrej Aerospace delivers landmark 200th set of BrahMos airframe assemblies. Handover ceremony took place virtually on 27th September 2021. It was attended by key leaders and mentors from BrahMos Aerospace Pvt Ltd, Defence Research & Development Laboratory (DRDL), Missile Systems Quality Assurance Agency (MSQAA) and Godrej & Boyce Mfg. Co. Ltd.
WE CARE... WE CELEBRATE...
A glimpse of employees engagement programs to bring in energy, enthusiasm and connect...
HEALTHCARE SESSIONS
Employees and their family members were vaccinated during the vaccination camps. Health care session was organised on 6th July 2021 for employees and their family members. Dr. Vasudev Kamat was invited to speak on “Myths & facts of Covid-19” and Dr. (Mrs.) Nita Kamat spoke on the “3rd Wave, effects on children and precautionary measures
DIWALI CELEBRATION
Atmanirbhar initiative
A session by Mr. S.M. Vaidya on Self Reliant India was organised on 14th August 2021. Through this session employees were made aware on the Nationwide Atmanirbhar initiative by the GoI and the opportunities for Godrej Aerospace.
This Diwali, we had organised lantern making competition. The theme was to make lantern in a most innovative way. The shopfloor was vibrantly lit with different types of lanterns. The teams displayed great amount of teamwork and there was enthusiasm seen across all departments. A memorable event.
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MQC Dept, IMMF LOB, Plant 8
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Rubber & Composites LOB, Plant 4B
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Academic success
Godrej Aerospace celebrated the Academic success of employee’s children on 20th August 2021. The highlights of the program were the talk by Mr Babu Bhaskaran, VP HR EPL limited on “Job market trend post pandemic”. The other session was an experience sharing on “Online Education System, Its pros & cons” by Mr Aryak Sathe, a 4th year engineering student.
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Welding Dept, Exports Fabrication LOB, Plant 4B
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Heat Treatment, Maintenance & Press Shop, Space LOB, Plant 16A
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WELDING PASSION & EXPERTISE TOGETHER NADCAP & AS9100 ACCREDITATED FACILITIES SINCE 2012
WELDING EXPERTISE GTAW (TIG), GMAW (MIG), Resistance (Spot and Seam) , Friction, Orbital (TIG), Electron Beam, Torch Brazing, Vacuum Brazing MATERIAL HANDLING EXPERTISE Titanium alloys, Nickel alloys (inconel), Aluminium alloys,Steel alloys (Precipitation hardened, Stainless Steel) Come, partner with us to experience innovation, precision and integrity. For more enquiries
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