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Overhaul Division Bangalore
Brief HistoryWelcome to Overhaul Division of HAL (Bangalore Complex).
Overhaul Division, one of the oldest Divisions of HAL was established in December 1940, has been involved from early days in the growth of aircraft industry in India. Between 1942 and 1945, the Division maintained and repaired varieties of aircraft like Liberator, Fortress, Mitchell, Dakota, Curtis Commando and PBY Catalina amphibian aircraft. After 1947, the Division oriented its activities to Major Overhaul of aircraft of Indian Air Force and Indian Navy and rendering 1st and 2nd Line Maintenance support to aircraft at various IAF and Naval Bases.
The Division, with over 80 years of experience in aircraft MRO has serviced over 4500 aircraft of different types and over 6500 Piston Engines.
The Division has since emerged as a world class MRO agency for the maintenance and servicing of state-of- the-art Military aircraft and associated accessories. It also renders highly competent maintenance and retrofit support at user’s works.
Currently it is the only Organization authorized to undertake Major Inspection of Mirage 2000 aircraft outside France.
Spread over an area of more than 10 hectares of land, Overhaul Division is empowered by a highly skilled workforce comprising of more than 1000 personnel supported by over 250 well qualified and experienced Executives.
The Division has a well equipped Accessories Repair / Overhaul Centre with excellent infrastructure to handle sophisticated Mechanical, Pneumatic and Avionic accessories. Highly sensitive testing equipment are employed during Repair / Overhaul of over 900 types of system accessories.
Division’s Quality CertificationsOverhaul Division has the following approvals & Quality Certifications:
- Director General of Aeronautical Quality Assurance (DGAQA), MOD, India
- M/s. Dassault Aviation, France
- M/s. BAE Systems, UK
- AS9100D & AS9110C certified
- ISO 14001:2015 EMS.
- Dedicated Hangars for each aircraft platform
- Well-equipped MRO centers for Repair /Overhaul of all aircraft system components
- Aircraft Painting facility
- Dedicated Hangars for calibration of Health & Usage Monitoring System of Hawk aircraft
- Wind Tunnel facility
- Specific to Type Testers and Equipment for all aircraft platforms
- Universal Test rigs for testing of Major aircraft system LRUs
- Non Destructive Testing facility
- Metrology facility
- Facility to test complete aircraft looms of Mirage aircraft
- Hydrostatic Stretch Test facility
- Oxygen and Nitrogen boosting facility
- Calibration of testers and measurements
- Clean room & ESD workstations
- Computerized Charging & Discharging facility
Overhaul Division has partnerships with a number of Approved and Accredited suppliers apart from
Original Equipment Manufacturers (OEMs).
Stringent Quality Control Checks are ensured during the approval / acceptance of outsourced components.
Outsourcing is resorted for following activities / services:
- Fabrication of project spares identified.
- Manufacture of Ground Handling Equipment and Ground Support Equipment.
- Fabrication of Tools and Fixtures.
- Calibration of Gauges.
- Jig referencing and Plating Operations.
- Work Package for Aircraft Painting.
- Work Package for Aircraft de-painting.
- Work package for cleaning of Rotables.
- Work Package for Looms dismantling and kitting of removed spares
A list of existing Approved Vendors for Outsourcing is given below. The Division is making continuous efforts to identify New Vendors and make further additions to this list:
Sl.
no. |
Supplier Name |
City |
Scope Of Work |
| 1 |
Aerospace Engineers |
Salem |
Machining Components |
| 2 |
Alpha Tocol Engineering Services Pvt. Ltd. |
Bangalore |
CNC Milling, Sheet Metal Components,Structural Assembly, Work Packages |
| 3 |
Amazon Engineering India Pvt Ltd, |
Bangalore |
CNC machining |
| 4 |
Amphenol Interconnect India Pvt. Ltd. |
Bangalore |
Manufacturing of Cable Assemblies, Panels & Laser Wire Marking and Electric Harness |
| 5 |
Applied Optics Inc |
Bangalore |
Indigenization of Laser Glass, Rear view mirrors, Toughened Glass, Quatrz Glass |
| 6 |
Ashwin Engineering Works |
Bangalore |
Conventional Machining |
| 7 |
AvioHeliTronics Infosystems Pvt. Ltd. |
Bangalore |
CNC Machining, GHE and Tools,JIGS and Fixtures. |
| 8 |
Concentra |
Bangalore |
Conventional and CNC Machining |
| 9 |
Craftair |
Bangalore |
GHE/Machining,Jigs,Fixture, Pres tools and and Fabrication Job work |
| 10 |
Karnataka Engg. Enterprises |
Bangalore |
Machining Components |
| 11 |
Karnataka Press Tools |
Bangalore |
Sheet Metal components |
| 12 |
Krafield |
Bangalore |
GHE/Machining,Jigs,Fixture, Pres tools and and Fabrication Job work |
| 13 |
Mahant Tool Room |
Bangalore |
Machining Components |
| 14 |
Merlinhawk Aerospace Pvt. Ltd. |
Bangalore |
Cables Assembly, Looms Aseembly, cable printing, Electrical assembly |
| 15 |
Micron Engineers |
Bangalore |
GHE/Machining,Jigs,Fixture, Pres tools and and Fabrication Job work |
| 16 |
Millennium Aero Dynamics Pvt Ltd |
Mumbai |
Painting / Depainting works |
| 17 |
Omega Engineers |
Bangalore |
Tools, Jigs, Fixtures and Moulds |
| 18 |
Prathibha Industries |
Bangalore |
Conventional and CNC Machining |
| 19 |
Qualidels |
Bangalore |
Machining Components |
| 20 |
Radel Advance Technolgy Pvt.Ltd |
Bangalore |
Electrical Assemblies |
| 21 |
Shanmukha Industries, |
Bangalore |
Conventional and CNC Machining |
| 22 |
Shirvanthe Technologies Ltd |
Bangalore |
GSE and GHE for Aerospace |
| 23 |
Sika Interplant Systems ltd |
Bangalore |
Electric cables and harness and Loom and LRU Manufacturing and testing |
| 24 |
Softec Services |
Bangalore |
GHE/GSE,Tool testers and Fabrication Job work |
| 25 |
Sree Hari Enterprises |
Bangalore |
Conventional and CNC Machining |
| 26 |
Sri Balaji Industries |
Bangalore |
Conventional Machining |
| 27 |
Sri Shakthi Industries |
Bangalore |
Conventional and CNC Machining |
| 28 |
Supratech |
Bangalore |
Conventional and CNC Machining |
| 29 |
SYS Industries |
Bangalore |
CNC Machining |
| 30 |
TE Connectivitiy Inda Pvt. Ltd. |
Bangalore |
Fabrication of Looms |
| 31 |
Weltech Industries |
Bangalore |
GHE/Machining,Jigs,Fixture, Pres tools and and Fabrication Job work |
| 32 |
Seven Hills Industries |
Bangalore |
Conventional and CNC Machining |
| 33 |
Cube Aerospace |
Bangalore |
Conventional and CNC Machining |
| 34 |
Byraveshwar Engineering Enterprises |
Bangalore |
Conventional and CNC Machining |
| 35 |
Sarvadih Industries |
Bangalore |
Conventional and CNC Machining |
| 36 |
Quality Tools |
Bangalore |
Precision Gear and Shaft Manufactring |
| 37 |
Saab Engineering |
Bangalore |
machining Components,jigs and fixtures,sheet metal component |
| 38 |
Sattva Aero Accessories and System pvt Ltd |
Bangalore |
Cnc turning,milling and Armatures Electrical assy |
| 39 |
Shree Ram Engineering |
Bangalore |
conventional machining and cnc turning |
| 40 |
HTL Ltd |
Hosur |
ELECTRICAL LOOM ASSY.AND TESTING,ELECTRICAL CABLES,WIRE HARNESS ASSY.FOR AEROSPACE APPLICATION |
| 41 |
Air Works India (Engineering ) Pvt Ltd. |
Hosur |
AIRPLANE FULL PAINTING,AIRCRAFT MAINTENCE, MAJOR SERVICE OF AIRCRAFT, STRUCTURAL REPAIR FOR AIRCRAFT AND COMPONENTS |
| 42 |
Acess Space Tec. |
Bangalore |
Work package for jehier cutting and stitching activity. |
| 43 |
Fluidyne Engineers India |
Mysore |
MACHINNED COMPONENT,INDIGENIZATION OF METALIC BELLOWS. |
| 44 |
Harini Industries |
Bangalore |
MACHINE SPARE PATS,CNC MACHINING,TOOLS ETC. |
| 45 |
M/S NAGA SAI PRECITECH PVT LTD (LN320) |
Bangalore |
Machined Components ,CNC Milling snd Turning |
| 46 |
M/S IFB AUTOMOTIVE PVT LTD (LI313) |
Bangalore |
Sheet metal components, Machined Components, CNC Machining, Turning ,GHE and GSE. |
| 47 |
M/S NeAL NAINI (LN321) |
Prayagraj |
MANUFACTURER,REPAIR AND SERVICE OF CABLE HARNESSES ,BOXES AND PANELS |
| 48 |
MECH WELL INDUSTRIES LIMITED (service) |
Nashik |
Painting / Depainting works |
Accreditation
- Overhaul Division has been accredited with AS 9100 D & AS 9110 C Quality Management Systems certificate by M/s NVT Quality Certification International.
- Overhaul Division has been certified with ISO 14001:2015 Environmental Management Systems by QMS certification services Pvt. Ltd.
Awards
- The Division is Honoured with a special award from the Chief of Air Staff, IAF in Nov 2002 in recognition of its yeoman services.
- The Division bagged the “Best Customer Services Award” for the year 2002-2003.
- The Division is Honoured with Safety Award “Utthama Surakasha Puraskara" by National Safety Council Karnataka Chapter, Bangalore for Best Safety Performance and Management Systems during the year 2009-2010.
- Two Quality Circle Teams of Overhaul Division won prizes during the National Convention in Dec 2014 in the Par Excellence and Excellent Categories.
- Two Quality Circle Teams of Overhaul Division won prizes during the National Convention from 18th to 21st December 2015 in the Excellent and Par Excellent Categories.
- Three Quality Circle Teams of Overhaul Division participated in National Convention on Quality Concepts (NCQC)-2016 organized by Quality Circle Forum of India (QCFI), Bhilai & teams won prizes during the National Convention in the Par Excellence, Excellent and Distinguished Categories.
- Two Quality Circle Teams of Overhaul Division won prizes during the National Convention in 2018 in the Par Excellence and Excellent Categories.
- Overhaul Division received the Best performing Division award in the category of Quality Assurance for the year 2020-21.
Kiran MK 1/ lA & IIA Overhaul Division is providing MRO support for Kiran MK 1/IA & IIA evolved from 1960 which are indigenously designed & developed by HAL.
- On completion of 800 flying hours, Aircraft are inducted to Overhaul Division for Major Servicing.
- Currently 111h Major Servicing is being performed by Division.
- Division is providing constant support to customer base for maintaining highest level of serviceability of most aged Aircraft despite challenges due to obsolescence
Jaguar(StrikejMaritimejTrainer) Overhaul Division is the approved repair agency for carrying out Major servicing of Jaguar Aircraft and its accessories by OEM M/s BAE Systems, UK.
MAJOR SERVICING
On completion of 2000 flying hours or 10 years whichever is earlier, Aircraft are inducted to Overhaul Division for Major servicing. The servicing include structural repairs, electrical checks & repairs, Fuel leak rectifications, NOT checks on structure, Looms replacement etc..
Mirage 2000 Overhaul Division is the only Service agency approved by OEM M/s. Dassault Aviation, France to undertake Major Inspection of Mirage 2000 Aircraft outside France.
MAJOR INSPECTION
On completion of 2000 Flying hours or 12 years of calendar life whichever is earlier, Mirage aircraft is inducted for Major Inspection at Overhaul Division. Major Inspection includes activities such as Structural repairs, Fuel tank sealant renewal, Hydraulic pipe line replacement, NOT checks, complete range of electrical loom testing etc.
HawkMK132 Overhaul Division is the Authorized Repair agency with non-exclusive Global rights for carrying out Repair and Overhaul of Hawk Aircraft.
MAJOR SERVICING
On completion of 2000 flying hours of 12 years, Hawk Mk 132 aircraft are inducted to Overhaul Division for undertaking Major servicing of Hawk Mk132 Aircraft including Structural, Electrical and Airframe repairs, Fatigue Modifications, NOT checks,Painting etc Jaguar Upgrade (DARIN 1/II/III) DARIN Ill UPGRADE
Overhaul Division is involved in upgrade of Jaguar Aircraft since four decade from NavWAAS to DARIN standard I/II/III. Currently DARIN Ill Upgrade is under progress.
Aircraft upgrade incorporates new avionics architecture including Advance Mission Computer. Engine and Flight Instrument System (EFIS). Modern navigation, EW and weapon delivery system, INGPS, Glass cockpit, Head up display. Incorporation of AESA Radar and Software Defined Radio (SDR). Smart Multi-Function Displays and Head-Up Display
Mirage 2000 Upgrade MIRAGE UPGRADE
Overhaul Division is involved in upgrade of Mirage 2000 Aircraft from H/TH to 1/TI standard since 2015.
Mirage upgrade of IAF enhances operational, maintenance and weapon handling capabilities.
Upgrade Incorporates:
Upgrade Incorporates:
- ROY Multimode RADAR
- Modular Data Processing Unit(MDPU)
- RLG based INGPS
- MLI 15538 and Digi bus
- Glass Cockpit
- Night Vision Goggle(NVG) compatible cockpit
- High Band Jammer(HBJ)
- Solid State Video Recording System(SSDVRS)
- Mission Planning and De-briefing tool
- Air to Air and Air to Ground Missiles
- Mission Computer (HAL design)
- Laser Designation Pod(LOP)
- Helmet Mounted Display System(HMDS)
- Counter Measure Dispensing System(CMDS)
- New Generation Precision Guided Missile (NGPGM)
- Air Combat Manoeuvring Instrumentation (ACMI)
Accessories MRO
Overhaul Division is involved in Repair, Overhaul,Accessories of Mirage, Jaguar, Hawk, Kiran, ALH ,Modification and testing of over 900 types of Cheetah, Chetak, Sea King, Avro, Mig 21, Mig 27, Dornier etc,
Division posses dedicated component workshops for all Aircraft Systems, Specific to type test equipment & Tools, OEM Testers, ATEs, Universal rigs for various systems.
Other facilities includes wind tunnel, Universal balancing m/c for wheels, ESD workstations & ESD flooring, Clean rooms, Environmentally controlled work areas, Environmental Test Chambers, Bearing hospital, Hydrostatic Stretch test facility, Generator test facility, Calibration facility, Metrology facility, Centrifuge, General Purpose Testing etc Overhaul Division has full-fledged infrastructure, facilities, Skills & Expertise and well established Quality Management systems to ensure highest level of customer satisfaction for the products and services rendered.
- Support to IAF Bases: Dedicated teams have been positioned at Tambaram for support of Kiran fleet and at Yelahanka for support of AN-32 aircraft. In addition, Teams are deputed at 11 IAF bases spread across pan India to provide support to IAF to meet their timely needs
- Supply of Spares/LRUs/GHE/GSE: Division is supporting customer bases through supplies of spare parts, LRUs, GHE/GSE required for first and second-line maintenance of aircraft at bases as and when required by customers.
- Defect Investigation / Failure Analysis/PWR: Division is undertaking Defect Investigation, Failure Analysis, Premature Withdrawal (PWR) study as and when required by customer. Repetitive failure cases are taken up for in-depth study and modifications are incorporated in the units to minimize the recurrence of such defects / failures in future.
- Training and Technical Assistance: Overhaul Division is supporting customers by providing training and technical assistance to meet their operation and maintenance requirement of the fleet.
CUSTOMER SUPPORT Light Combat Aircraft ( LCA )  Overhaul Division has initiated establishment of facility to undertake Major Servicing of LCA.
Ageing Study and Major Inspection 3 of Mirage Aircraft: 
- Ageing Study 3 (AGS 3) of Mirage aircraft by M/s Dassault Aviation, France (OEM) is planned in FY 2023-24 (2 a/c) and FY 24-25 (2 a/c) at Overhaul Division.
- On completion of AGS3, entire Mirage fleet will undergo Major Inspection 3 at Overhaul Division.
Transformation of Mirage 2000 B to Mirage Tl standard 
- Transformation of Mirage 20008 to Mirage 2000 Tl standard on two aircraft in under progress at Overhaul Division with the support of OEM M/s. Dassault Aviation, France.
- Post completion of transformation, Overhaul Division will undertake Major Inspection and upgrade.,.
100% Loom Replacement on Jaguar Aircraft 
- Facility set up for undertaking 100% looms replacement on Jaguar aircraft has been initiated. On readiness of facility, Overhaul Division will undertake 100% looms replacement on Jaguar aircraft inducted for Major Servicing/Upgrade during FY 2023-24.
- As per tentative plan, 100% Loom change is planned is expected to be completed by FY 2036-37.
Modification of Kiran MK II Aircraft to Unmanned Aerial Vehicle/ Optionally Piloted Vehicle( UAV/OPV) 
- Conversion of Kiran MK II Aircraft to Unmanned Aerial Vehicle/ Optionally Piloted Vehicle is currently being designed and developed by HAL Research Centre. Overhaul Division will undertake modification involving integration of new systems/modification of existing systems, ground run, flight trails and flight acceptance.
- Development of Automatic Digital Flight Control System and Remote Piloting for Fixed Wing Aircraft.
PotentialArea of Business Collaboration
- Major Servicing of Mirage 2000 aircraft,Hawk MK132 aircraft
- MRO of Components fitted on Mirage, Jaguar, Hawk, Kiran, Cheetah/Chetak helicopter,ALH , Sea King, Avro, Mig21, Mig27, Dornier etc.,
- Servicing of aircraft clocks/chronograph
- Customized Aircraft Series upgrade
- Modifications on aircraft and components
- 100% loom replacement on aircraft
- Manufacture of Radome
- Defect investigations
- MRO support at customer sites
- Civil Component MRO
- Utilization of NOT and metrology facility
- Ultrasonic Phased Array testing
- Magnetic Particle testing
- Radiography
- Eddy current
- Liquid Penetrant Testing
- Calibration of testers and measurements
- Utilization of existing testing facilities
- Wind Tunnel facility for testing of Angle of Attack probes(airspeed up to 300 knots)
- Environment chamber(- 70 Deg C to+ 180 Deg C)
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- Aircraft painting facility
- HUMS testing for Hawk aircraft
- Facility for Pre-installation checks of Mirage LRUs
- UniversalHydraulic testing facility
- UniversalFuel testing facility
- UniversalPneumatic Test Rig
- Generator Testing facility
- Computerized Charger Discharger facility for Battery
- Fluid contamination checks facility
- Hydrostatic Stretch Test facility (Max testing pressure 7000 psi)
- Nitrogen Boosting facility with capacity of Max Pressure up to 4000 Psi
- Oxygen Booster facility with Max Pressure up to 2600 Psi
- Lox Charging Facility for charging of Liquid Oxygen for various aircraft(950 litres Lox storage tanker capacity)
- DigitalUniversal Balancing Machine
- Digital computerized universalBalancing Facility for balancing of half hubs of main and nose wheels of various aircraft can be carried out on the rig with an accuracy of 0.001 Nm. (Max dia.650 mm and Max wt. 200 kg)
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For Further Details Please Contact:
General Manager
Overhaul Division
Hindustan Aeronautics Limited
P.O. Vimanapura
Bangalore - 560 017
Karnataka State
India
E-mail: gm.ohl@hal-india.co.in
Telephone : +91 -080 - 22313639
Fax : +91 -080 - 22311181
Customer Services :
Telephone / Fax : +91 -080 - 22318225.
Projects:
E-mail: s.anitha@hal-india.co.in
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