AMRITA VISHWA VIDHYAPEETHAM

Internship report carried out in

HINDUSTAN AERONAUTICS DIVISION

( AEROSPACE DIVISION )
New thippasandra post, Beangalore-560075

Submitted by

Ashwini L (BL.EN.U4EIE15008)

Kommuri Poojitha (BL.EN.U4EIE15042)

Maanasa Parameswaran (BL.EN.U4EIE15053)

Naga Pavani (BL.EN.U4EIE15058)

In partial fulfillment for the award of degree of

Bachelor of engineering in

ELECTRONICS AND INSTRUMENTATION ENGINEERING

PREFACE

Industrial training in true sense has been included in curriculum to make the student well
versed with the technical procedure of various industries, the basic criteria for management of
various resources in a company or industry.

The educational institution sole aim by industrial training is to improve the technical knowledge
and to have a hand on experienced to make them realistic in thinking, to understand the
procedure for manufacturing keeping mind the minute detail which will benefit the customer
like the no learning is proper without implementation.

Doctors, Lawyers, hotel management student surely hold an upper hand. It’s because right
from second year of their graduation they are made to face the world and their problems with
a tender mind.

Unlike the pitiable engineers like us who are completely isolated from industry. Therefore there
should be industry institutions made compulsory for every engineering institute.
ACKNOWLEDGEMENT

With deep devotion I thank all mighty god for blessing me with desire, intention, inclination,
will, ability, guidance hope and achievements of required goal.

The present dissertation entitled “AEROSPACE division” in fulfillment of industrial Training at

Hindustan Aeronautics limited.

I would like express my gratitude to all those who gave the possibility to complete this training.
I want to thank Hindustan Aeronautics limited for giving me permission to commence this
training in the first instance, to do the necessary research work and to use Technical
Departmental data. Would take this opportunity as a proud privilege to express my deep felt of
gratitude to Mr.M.P.Parameswaran (SR-HM,LHWC).

Last but not the least, I also wish to acknowledge my indebtedness to the staff of H.A.L. without
whose co-operation, this training would not have been successful. The training H.A.L. Bangalore
was full of responsiveness with the opportunity to correlate the theoretical knowledge with the
opportunity to learn the work carried out here, got a glimpse of new environment and hard
work of industrial unit.
 DECLARATION
We hereby declare that this training report entitled “Internship in HAL aerospace division”
submitted by us in the fulfillment of training at HAL is an authentic record of our own work
carried out at Hindustan Aeronautics limited, Bangalore.

DATE: 31/05/18

PLACE: BANGALORE

Ashwini L

Kommuri Poojitha

Maanasa Parameswaran

Naga Pavani

( Amrita school of engineering,Bangalore)

ABSTRACT

Aerospace, materials, frequently metal alloys, that have either been developed for, or have
come to prominence through, their use for aerospace purposes. These uses often required
exceptional performance strength or heat resistance, even at the cost of considerable expense
in their production or machining. Others are chosen for their long term reliability in this safety-
conscious field, particularly for their resistance to fatigue. India’s growing involvement in space
exploration is reflected in the establishment of a world class manufacturing base for space
worthy hardware. This leads to a demand of technical expertise to fabrication large size
Aluminum Alloy riveted structures, welded propellant tanks and water tanks. The development
of glass fibers, in the beginning of the 1950s, and boron fibers, in the beginning of the 1960s,
and new resins like epoxy and polyester gave a lot of impulses to the research of composite
materials in Aerospace structures. Modern Aerospace structures are mainly consist of CFRP i.e.
carbon fibers is fabricated at a particular temperature and pressure conditions.

Keywords: Riveted, Aluminum alloys, propellant

CONTENTS

1) Introduction

2) History

3) Aerospace division

4) Products of HAL

5) Departments of aerospace division

* PSLV/GSLV welding shop

* PSLV welding

*CNC shop/ Maintenance

* Tool panning and tool design

*Methods engineering and process shop

*Programme engineering and outsourcing

*MK III/machine shop

*IT department

*Quality control

*Purchase and stores

* Finance
INTRODUCTION

HAL manufactures 11 type of aircraft from in house R&D, 14 types of license productions
(including 8 types of Aero engines),Hindustan Aircraft Private Limited(HAPL) was incorporated
on 23.12.1990 by Walchand Hirachand as a private aircraft manufacturing company. In March
1941 Government of India became one of the shareholders in the company by holding 1/3 rd of
its paid up share capital. Subsequently, in 1942 it took over the management of the company.

Fighter jets and bomber aircraft were produced in collaboration with Inter Continental Aircraft
Company of the USA. In December 1945, after the WW II the company was placed under the
administrative control of Ministry of Defense.

In August 1963, Aeronautics limited (AIL) was incorporate as a company wholly owned by the
Government Of India to manufacture MIG 21 aircraft under license from Russia.

In October 1964, AIL and HAPL was merged to form Hindustan Aeronautics limited (HAL) with
its principal business being design development, manufacture repair and overhaul of aircraft,
helicopter, engines and related systems like avionics, instruments and accessories.

By the end of 2006 HAL has produced around 3400 aircraft, 3600 aero engines and overhauled
around 8320 aircraft and 27800 engines.

HAL’s major supplies/services are to Indian Air Force, Indian Navy, Indian Army, Indian Coast
guard and Border Security Force. It also supplies transport aircraft and helicopters to airlines
and state governments. Its major partner is ISRO for which it supplies space vehicles.
 HISTORY

The company which had it’s origin as the Hindustan Aircraft Company was incorporated on 23
Dec 1940 at Bangalore by Shri Walchand Hirachand and a farsighted visionary in association
with the Government of Mysore with an Authorized Capital of Rs.4 crores and with the main
aim of manufacturing aircraft in India. In March 1941, the Government Of India became one of
the shareholders in the company holding 1/3rd of its paid-up capital and subsequently took over
its management in 1942. In collaboration with the Inter Continental Aircraft Company of USA,
HAL commenced its business of manufacturing of Harlow Trainer, Curtiss Hawk Fighter and
Vultee Bomber Aircraft.

In December 1945, the company was placed under the administrative control of Min. of
Industry and Supply. In January 1951, Hindustan Aircraft Pvt Ltd. was placed under the
Administrative Control of Ministry of defense. The Company had built aircraft and engines of
foreign design under license, such as Prentice, Vampire and Gnat aircraft. It also undertook the
design and development of aircraft indigenously. In August 1951, the HT-2 Trainer aircraft,
designed and produced by the company under the able leadership of Dr.V.M.Ghatge flew for
the first time. Nearly 2

00 Trainers were manufactured and supplied to the Indian Air Force and other costumers. With
the gradual building up of design capability, the company successfully designed and developed
4 other aircraft i.e. two seater ‘Pushpak’ suitable for flying clubs, ‘Krishak’ for Air Observatory
Post (AOP) role, HF-24 Jet Fighter and the HJT-16 Basic Jet.

Meanwhile, in August 1963, Aeronautics India Ltd was incorporated as a Company wholly
owned by the Govt. of India to undertake the manufacture of MiG-21 aircraft under license. In
19 June 1964, the Aircraft Manufacturing Depot which was set up in 1960 as an Air Force unit to
produce the Airframe for the HS-748 transport aircraft which was transferred to AIL. Soon
thereafter, the Govt. decided to amalgamate HAL, with AIL so as t conserve resources in the
field of aviation where the technical talent in the country as ltd. And to enable the activities of
all the aircraft manufacturing units to be planned and co-ordinated, Amalgamation of the two
companies was brought about on 1st October 1964 by an Amalgamation was named as HAL
with its principal business being design, development, manufacturer , repair and overhaul of
aircraft, helicopter, engines and related systems like avionics, instruments and accessories.
AEROSPACE DIVISION

Aerospace Composites Division ( erstwhile Composites Manufacturing Division) was conceived

as early as the dates of design of Light Combat Aircraft (LCA) & Advanced Light Helicopter (ALH)
and has experience in manufacturing and realizing aircraft structures made of composites. Over
the years the scope and role of the facility was defined and refined from ‘Advanced
Composites Shop’ to ‘Centre of Excellence’.

Currently, the Division is manufacturing the composite structural parts for Advanced Light
Helicopter (ALH), Light combat aircraft (LCA), Light Utility Helicopter(LUH), PSLV/GSLV.

The Division is equipped with modern infrastructures in Plant and Equipments like
Environmental Control Area of various Classes, -18 degrees Celsius cold store, Autoclaves, High
precision 5-Axis CNC Machine Centers, Automated Ply Cutting Machines, Surfaces
Enhancement Machine (shot peening), Hot Platen Presses, Computer Controlled Air Circulating
Ovens, Laser Projection Systems for Lay-up, CT-scan, Ultrasonic C-scan, Coordinate Measuring
Machines, Laser Tracker, Universal Testing Machines and Material test laboratory for
composite material testing.
 MISSION, VISSION AND VALUES

MISSION

To achieve self reliance in design, development, manufacture, upgrade and maintenance of

aerospace equipment, diversifying into related areas and managing the business in a climate of
growing professional competence to achieve world-class performance standards for global
competitiveness and growth in exports.

VISSION

Customer satisfaction

We are dedicated to building a relationship with our customers where we became partners in
fulfilling their mission. We strive to understand our customers’ needs to deliver products and
services that fulfill and exceed all their requirements.

Commitment to total quality

We are committed to continuous improvement of all our activities. We will supply products and
services that confirm to highest standards of design, manufacture , reliability, maintainability
and fitness for use as desired by our customers.

Cost and time consciousness

We believe that our success depends on our ability to continually reduce the cost and shorten
the delivery period of our products and services. We will achieve this by eliminating waste in all
activities and continuously improving all processes in every area of our work.

Innovation and creativity

We believe in striving for improvement in every activity-involved in our business by pursuing

and encouraging risk-taking, experimentation and learning at all levels within the company with
a view to achieving excellence and competitiveness.

Trust and team spirit

We believe in achieving harmony in work life through mutual trust, transparency, co-operation
and a sense of belonging. We will strive for building empowered teams to work towards
achieving organizational goals.
Respect for the individual

We value our people. We will treat each other with dignity and respect and strive for individual
growth and realization of everyone’s full potential.

Integrity

We believe in a commitment to be honest, trustworthy and fair in all our dealings. We commit
to be loyal and devoted to our organization. We will practice self discipline and own
responsibility for our actions. We will comply with all requirements so as to ensure that our
organization is always worthy of trust.

VALUES

The Vigilance Manual Vol-I focuses on Organization and Policies of the Vigilance Department
which has been carefully devised keeping in mind not only the latest developments in the field
of Investigation, Leveraging of Technology which is so essential for meaningful Vigilance work,
but also the Goals and objectives.

OBJECTIVIES AND STRATEGIES

OBJECTIVIES

 Ensure availability of Total Quality People to meet the Organizational Goals

and Objectives.
 Facilitate continuous improvement in knowledge, skills and competence
 Promote a culture of learning, innovation and achievement with emphasis on
integrity, credibility and quantity
 Motivate workforce through empowerment of individuals and team-building.
 Play a pivotal role directly and significantly to enhance productivity,
profitability and the quality of work life.

STRATEGIES

 Total alignment with Corporate Strategy.

 Tone up Human Resources at optimum lever to meet the objectives and goals of
the Company.
 Identify, Build, Analyze and Upgrade the knowledge and Skills through Training
Re-Training, Multi-skilling etc.
 Cultivate Leadership with Shared Vision at various levels in the Organization.
  Focus on Development of Core Competence in high-tech areas.
 Build cross-functional teams.
 Promote vision, mission and values throughout the company.
 Encourage performance culture that Rewards, Recognizes & Motivates.

DIVISION OF HAL

All over India HAL has 7 divisions; these are dedicated for different purposes related to the
manufacturing of commercial, fighter aircraft and Aerospace Structure. The divisions are as
follow:

1. Bangalore Division
It is divided into 5 divisions:
a) Aircraft division which also consists of a runway
b) Engine division which is indulged mainly in manufacturing LCA Engine
c) Helicopter division
d) Overhaul division
e)Design bureau
f) Aerospace division

2. Nasik Division
It is currently dealing with Russian accessories repair, overhaul and manufacturing which are
used in aircrafts.

3. Kanpur division
It is dealing with assembly of whole commercial aircrafts like Pushpak, Dornier and other major
products are DO-228, HPT-32 and Civil aircrafts etc.

4.Lucknow Division
It is an accessories division which deals with manufacturing of more than 1400 accessories like
alternator, generator, tachometer, tachogenerator, landing gear, wheels, breaks, GSE, GHE,
ECS, etc.

5.Korwa Division
It also deals with design and manufacturing of accessories and other major products are INS,
HUDWAC, NAV attack LRMTS, FDR.

6. Koraput Division
It’s indulged in assembly of engines of aircrafts.
7. Hyderabad Division

It is an accessories division. They manufacture accessories like Surveillance Radar, Precision

Approach Radar, INCOM,RAM,IFF,VHF/UHF(5).

PRODUCTS OF HAL

AIRCRAFT

Aircraft Research and Design Centre (ARDC), began as the Engineering Dept. of HAL during
1948-49 and has grown into a full-fledged R&D Centre and has designed several aircrafts
ranging from basic piston Trainers namely HT-2, Pushpak to the frontline combat.

ARDC has full spectrum of expertise in all facets of aircraft design & development acquired
through sustained learning and R&D. Our proven capabilities are backed by rich in-service
experience spanning over seven decades. ARDC has extensive state of the art test facilities and
full-fledged manufacturing infrastructure for building aircraft prototypes and test articles,
simulation and analysis tools to support flight development programmes.

HELICOPTERS

The division is supported by the co-located R&D centre-Rotary Wing Research Design Centre.
The MRO division caters to the Maintenance, Repair & Overhaul activities of helicopters. The
Rotary Wing Academy focuses on training of pilots.
HAL started manufacturing of helicopters in 1962, by entering an agreement with M/s SUD-
AVIATION for production of Aloutte 3 Helicopters. The first Chetak in ‘Fly’.

POWER PLANT

In a significant move to harness wind power and promote renewable energy source, Mr. T
Suvarna Raju, CMD, HAL today inaugurated 6.3MW wind energy power plant would be used for
captive from here. The power generated from this plant would be used for captive energy
consumption at Bengaluru.

AEROSPACE

Aerospace Division is engaged in the manufacture of Aluminum alloy, riveted structures and
welded tankages of conical, cylindrical and other shapes with different types of detailed parts
such as sheets, rings, brackets, stiffeners, bulkheads, panel bolts, nuts, rivets etc. Some of the
important structures manufactured are heat shield assembly, nose cone assembly and tank and
shrouds used in satellites.
DAY 1 17/05/18

DEPARTMENT: PSLV/GSLV ASSEMBLY SHOP

Objective: Continual quality improvement and customer satisfaction.

Scope: Covers light alloy riveted structure, mechanical assemblies and also composite structure
produced as per production plan and customer requirement.

PSLV/GSLV assembly shop involves in fabrication of light alloys riveted structures for PSLV/GSLV
and composite material structure. The structures are fabricated as per procedure plan, utilizing
the resources like techniques, assembly jigs and production tool in coordination with planning,
production engineering and quality control department.

This assembly shop includes assembly facilities including high precision vertical assembly jigs
with staging for assembly of structures size varying from 3.2m diameter & 8.3m diameter to 5m
diameter and height of 10.63m.

The key parameters are height, flatness, concentricity, parallelism and height. All these are
ensured through assembly jigs.

Riveting: Riveting is a forging process that may be used to join parts together by a metal part
called rivet. The rivet joins the parts through adjacent surfaces. A straight metal piece is
connected through the parts, then both ends are formed over the connection and joining the
parts securely.

PSLV heat shield: A heat shield is designed to shield a substance from absorbing excessive heat
from an outside source by either dissipating, reflecting or simply absorbing the heat. It is often
used as a form of exhaust heat management. During launch the spacecraft is at a very great
speed, causing tremendous heat build up heat from friction with air, requiring a heat shield to
protect the spacecraft.

Assembly jigs for PSLV Assembly jigs for GSLV MKII

1.IRS-P4 satellite structure 1. Heat shield

2. Heat shield 2. Space craft

3. Payload adaptor 3. Payload adaptor

4. PS4 tank 4. Upper stab adaptor

5. Inter-stage ¾ 5. Lower stab adaptor

6.PS3 adaptor 6. Liquid hydrogen tank

7.Inter-stage 2/3 U 7. Lower truss assembly

8. Inter-stage 2/3 L 8. Inter-stage 2/3 L

9. PS2 tank 9. GS2 tank

10.Inter-stage ½ U 10. Thrust frame

11. Thrust frame 11. Inter-stage IS ½ U

12. Water tank 12. Inter-stage IS ½ M

13. Feed line-N 13. Inter-stage IS ½ V

14. Feed line-U 14. Liquid strap on (L-40)

15. Inter-stage ½ L 15. Strap on base shroud

16. Strap nose cone 16. Core based shroud

17. Core based shroud 17. AFT end closure

 DAY 2 18/05/18

PSLV/GSLV WELDING SHOP

The scope operation of this shop involves in the range from making weld sub assembly, welding
the sub assembly to make full tank, machining of tank, leak check, cleaning and making of tank
ready for final dispatch to the costumer.

PSLV welding shop was started in the year 1988 for the manufacture of PS2 tank, water tank
and feed lines for PSLV launch vehicle. Later it was taken up for the welding of propellant tanks,
water tank and feed lines for GSLV launch vehicle.

Material used:

AA7020, AA6061 and AA2219 Aluminum Alloy

Customer:

Liquid Propulsion System Centre

Welding:

AC TIG, DCSP-TIG,FSW

Welding Process at PSLV welding shop:

1. Rotary welding process for welding of nozzles.

2. Manholes cover welding process on column and boom manipulator.
3. Dome to end ring welding on column and boom manipulator.
4. L-Seam welding process for L-Stem welding of shell segment.
5. Meridian welding of petals on column and boom manipulator.
6. Cir -seam welding for welding of shells and welding of shells of domes.
Friction Stir Welding:

Friction stir welding(FSW) is a solid -state joining process that uses a non-consumable tool to
join two facing work pieces without melting the workpiece material. heat is generated by
friction between the rotating tool and the work piece material, which leads softened region
near FSW tool.

Equipment in welding shop:

1. Bode cir-seam weld lathe.

2. Bode L-seam welding machine.
3. Bode column and beam manipulator.
 4. V-V-weld Centre.
5. Bode rotary welding machine.
6. A. K. Hi-tech boring machine.
7. Manual welding machine.
8. MK III-PS2-L40 driving tool for cir-seam welding.

Test carried at the specimen after welding:

Destructive tests

1. Tensile test.
2. Impact test.
3. Fatigue test.
4. Bend test.
5. Burst test.
Non- destructive tests

1. Radiography.
2. Ultra-sonic flow detector.
3. Dye penetrate test.
4. Leak check.
5. Laser tracker.
Functions of PSLV welding shop

1) Process steps

2) Monitoring welding operation

3) Monitoring key characteristics

4) Monitoring of changes in design process

5) Control of customer property

6) Identification of traceability/ configuration control

7) FOD control

8) Environmental control

9) Safety measure
DAY 3 19/05/18
CNC MAINTAINENCE

The CNC machine shop provides different computer numeric machine required for production
of complex contour and aerospace structures. The quality management system in CNC shop is
to ensure quality of the product and schedule output. The machine loading plan is provided by
scheduling and programme engineering dept. and items are loaded to CNC shop along with all
the documents by the loading group of CNC progress.

PROCESSES CARRIED OUT IN CNC SHOP:-

1. Machine wise arrangement of the detail parts and sub assemblies as per the loading plan of
scheduling and decision by daily production review meeting.

2. CNC machining of the detail parts and sub assemblies for riveted and welded structure of the
project PSLV,GSLV MK-2 & MK-3, INSAT and IRS in CNC shop and tooling as required.

3. To follow master sheet, Route card, Job tickets, monitoring and control of key characteristics
indicated in the drawing and process documents.

4. To coordinate for various support activities like process planning, scheduling, CNC
programming, tool planning, calibration of instrument, equipments, machine tool and
maintenance to implement corrective actions

5. Planning of tool, accessories and consumable for shop.

PROCESS VERIFICATION:-

1. Program checking using vericut.

2. Carry out skin cut for milling operation
3. Check the dimension
4. Finish machining and offer to inspection
5. Study inspection report for correction required in program and implement correction
6. Carry out documentation

CMC programme

G codes, M codes

Software: CAM software, simulation software

Machines found in cmc shop

 1) Machining center BMC 100(5)

GENERAL FEATURES:

Table diameter: 1250mm

Number of pallets: Two

Axes: X, Y, Z, A & B

Stroke: X-Axis:1500mm

Y-Axis:1500mm

Z-Axis:1250mm

A-Axis:+10deg t0 -110deg

B-Axis:0 to 360 degree

Speed range: 1rpm to 300rpm

Axis feed rate: X –axis:7200mm/min

Y-axis:6000mm/min

Z-axis:10000mm/min

A&B axis:500mm/min

Spindle taper: BT50

Permissible load on table: 6 tons

Position accuracy: X & Y axis: +/- 0.01mm/m

Z axis: +/- 0.01mm/m

Repeatability accuracy: Axis X & Y:0.015mm

Z Axis:0.015m

Components: wing bay, IMU mounting, Bulk head rings, thrust frame, feed line assembly
L40 INTEGRATION

L40 is a liquid booster can figured as strap on to the solid care (S139) of GSLV. Four such strap
ons and the S139 to which L40 are attached comprise the first stage of GSLV core stage burns
out at 100sec.strap on 50sec.

Stage decription:-

1. L40 stage is a liquid booster rocket consisting of mainly three Al alloy structure
SONC, ITS, SBC and two propellant tanks.
2. Propellant is stored on two separate identical Al alloy and cylindrical tanks i.e
fuel and oxidizer.
3. Oxidizer- N204(Nitrogen Tetra Oxide) Fuel-UH25(mixture of unsymmetrical
dimethyl hydrazine and hydrazine hydrate)
4. 40 tons of propellant is loaded in stage at launch pad.
5. Water is also used in the propulsion system and it is stored in stainless steel
toroidal tank mounted in between propellant tank.
6. The power plant of the stage is a turbo pump feed vikas engine.

L40 stage specification:-

1. Strap on Nose cone Assembly

2. N tank
3. Inter tank skirt
4. U tank
5. Strap on base shroud(SBC)
6. FIN
7. Thermal shroud
8. Vikas engine

Process involved in L40 integration:-

1. Metal cutting on structure

2. Pipe line suiting, welding and pressure testing
3. Thermal painting of structure
4. Fitment of modules and pipelines
5. Electrical harnessing
6. Leak check
7. Preparation of tank, pad bonding, leak check and painting
8. Horizontal integration of all structure and tanks
9. Theodelite alignment of stages
10. Cold gimbal test and leak check
11. Dismantling, packing and dispatch of SHAR
 DAY 4 21/05/18

TOOL PLANNING AND DESIGN

Segment are joined by drilling and riveting methods. It’s a cold forging method

Method department-receives components and drawing from customers

Bottom portion: CBS

Top portion: heat shield (11m height)

Jigs: holds all the components

Jigs and toll order: any department to communicate

Tool engineering-

 Design
 Planning
 Inspection

Tendering: it is a purchase order method

Tool engineering department is a branch of production engineering department that caters to

the requirements of all manufacturing and assembly shops in ASD for providing tooling support
of all the projects like PSLV, GSLV, MK II, GEOSAT, IRNSS, INSAT, HAWK.

For effecting functioning of the department, the activities of tool engineering department are
divided into 4 units:

1) Tool planning and manufacturing design

2) Tool design unit

3) Tool progress/ maintenance unit

4) Tool room/ jig assembly unit

Process objective: Design, manufacture, supply, prove out and modifications of tools required
for different manufacturing them. Planning and procurement of standard tool required in
manufacturing shops.

Scope: Covers all the tooling activities in division.

Tool design: Design and development of jigs and fixtures, special tools, GHE, special inspecting
gauges, cutting tools.

Providing proper, practical, measurable dimensions and geometrical accuracies in the drawing
which have got direct impact on the quality. Participation during first half prove out.

Tool planning/ tool manual: Realization of jigs, fixtures, special tools etc either in house
including sister divisions or through outsourcing method. Planning and procurement of raw
materials. Procurement of cutting tools. Re-sharpening/ reconditioning of cutting tools. Storage
and maintenance of production tools.

Jig assembly: Periodic referencing of jigs for sub assembly and main assembly. Modification and
rework of jigs. Up-gradation of existing jigs in consultation with tool design or to improve the
quality.

Process of jig setting: Collect and study the tool drawing

Manufacture of all details

Construction of assembly jig

Setting of dimension and geometrical key

Verification through remote measuring

Customer co-ordination for final clearance.

DAY 5 22/05/18

METHODS ENGINEERING AND PROCESS SHOP:

Method Engineering- The method engineering department is the key area of production
engineering department of aerospace division providing the necessary process and identifying
the process equipment for product realization for the product of ISRO, DRDL, and BDL project in
division.

The department works with the customers to understand specification and requirement and
fulfill the same through effective process planning.

Process Description:-

1. Feasibility study
2. Resource planning
3. Preparation of estimate and submission of quotation
4. Preparation of SOP, tooling requirement, material and process plan
5. Continuous interaction with customers to understand and product is made to their
requirement
6. Control of customer supplied documents and documents released by the department
7. Update of process due to design changes and corrective actions
8. Preventive actions on continuous improvement basis

Process shop:-

1. Anodizing of Al- alloy components

2. Chemical milling of Al- alloy component
3. Chromate treatment of Mg- alloy component
4. Cadmium plating of alloys steel component
5. Cleaning of component for welding, heat treatment etc.
6. Vacuum impregnation of Mg- alloy
7. Epoxy and etch priming of CSLV, PSLV AND CAENATION PROJECT
8. Crack detection of PSLV, GLSV and carnation project
 DAY 6 23/05/18

PROGRAMME ENGINEERING,OUTSOURCING AND PROCESS SHOP

The outsourcing department is one of the key departments in HAL-ASD for execution of
outsourcing activities. They are mainly responsible for realization of parts/assemblies which are
planned for outsourcing.

It functions with the objective of realization parts/assemblies from competent and reliable
sources meeting the quality and delivery requirements with competitive price.

PROCESS SHOP

Common materials used: Aluminum: Light weight,2.9g/cc, used in space and aircraft
applications.

Magnesium: 1.7g/cc, used in missile applications

Steel: 7.8g/cc, used in engines

Titanium: 4.3g/cc, used in cryogenic stages

Heat treatment shop: Processes used in this shop are annealing(softening),

solutionising(hardening),ageing.

The paints used in process shops are etch primer, epx primer, epx white primer.

Tank 1: Hot water sealing tank

DM water

Operating temperature: 93*c and above

Immersion time: 10min

pH value: 5.0-6.5
Tank 2: Alkaline cleaner tank

DM water

Blue old industrial cleaner 5%

Operating temperature: 50-60*c

Immersion time: Up to 50min

pH value: 9-11.5
 DAY 7 24/05/18

MK III AND MACHINE SHOP

Components of MK III: Heat shield, spacecraft, equipment bay, C25 stage, RCS thrusters,
AFT.STUB adaptor(collet mechanism), S200 FWD joint, inter-stage 112U inter-stage 112M, L110
stage, S200 stage, S200AFT joint, FNC tank.

Machine shop: The sheet metal and general machine shop is responsible for the manufacture
and supply of detail parts for the manufacture and supply of detail parts for HAWK, NIRBAY,
PSLV, GSLV, CARNATION, INSAT and GSLV MK III projects.

The general machine shop supports tooling requirements of the division for the above projects
to the extent of sharpening of cutters, rework of tooling elements like clamps etc.

The sheet metal shop is involved in shearing, sizing, rolling, dressing, deburring, burnishing,
layout and drilling.

The general machine shop is involved in turning, milling, drilling and grinding.
 DAY 8 25/05/18

IT DEPARTMENT

The computer services department in ASD was established during April 2001. The division was
initially sharing hardware resources with helicopter division and later acquired on independent
HP90000-D-330 server.

The AS9100C QC system was created to support the aviation, space and defense industries.

SCOPE: The IT department is responsible for providing technology support for the entire
division.

The support includes IT infrastructure, upgrades of the system, network infrastructure and
information security.

The IT department is responsible for hardware & software installation, trouble shooting and
upgrade facilities.

ERP support.

OBJECTIVE: 1) To resolve issues of all computer users in less than a week

2) Regular backup of data every alternate day.

3) Maintenance of computers and their peripherals to ensure at least 90% up time.

FUNCTIONS: 1) Application and software department

2) Upgrading of the hardware and software

3) Providing various MIS information regularly

4) Generation of ADHOC reports when required

Facility in the IT department

OS: Oracle 10g version 10.1.2

HP UNIX 11.2

HP UNIX 10.20

Windows XP professional

Windows 2007
 Windows 2008

Novell netware

Languages, tools, suits: MF-COBOL,Pro-COBOL, C & Pro*C

System backup- Twice in a year

Database backup- Daily

Application backup- Once in two months

 DAY 9 26/05/18

QUALITY CONTROL

The quality control is a vital functional department in ASD with the responsibility of ensuring
the quality of products to the specified requirements and customer satisfaction.

It was established in the year 1985.

Objective: To coordinate the quality control activities in all the functional areas from the stage
of raw materials to final delivery of product to customers.

Coordinates with agencies like MSQAA, RQS for stage clearance and final clearance of the
products. The QC department is also responsible for bringing out the deficiencies of the
processes product quality.

Verification of purchased products: The purchased products are verified at receipt inspection to
ensure that they meet the specified purchase order requirement.

The QC department should ensure that the purchased product is not used or processed until it
has been verified as conforming to specified requirements unless it is released under positive
recall procedure.

Assembly final inspection:1) PSLV/GSLV tankages welding and NDT

2) Drop tank carnation welding, NDT for tanks and structures

3) HAWK RRE assembly inspection

4) PSLV/GSLV and MK III assembly inspection

5) L-40 integration inspection

 DAY 10 28/05/18

PURCHASE AND STORES

All purchase requirements are to be properly assessed and are to be formally authorized by the
competent authority as per delegation of powers in force. The provision of the stores needs to
be done with utmost taking into account the available stock, outstanding dues/supplies, and
average life of the equipment.

MATERIAL PURCHASE REQUEST (MPR): MPR for Project Materials should accompany
with Material
adequacy statement / review sheet based on Production Programme/ task (includes
manufacturing and ROH programme). The bill of material certified by Production Engineering
and amended from time to time is the base document. In respect of Repair/Overhaul
programme for the Mandatory/Non mandatory spares along with P-factor to be certified by
Production Engineering. For
recurring requirements efforts should be made for entering into LTBAs/LTRAs. However where
MoQ/ Standard package size is involved the same can be considered.

b. CAPITAL PURCHASE REQUEST (CPR): shall be raised by the Head of Planning

or any other officer specifically authorized for purchasing the sanctioned capital equipment.

c. URGENT PURCHASE REQUEST (UPR): Form

Annexure-09
shall be used

d. PETTY PURCH.ASE REQUEST UPTO Rs. 15000 (PPR)

Purchase Committee (PC)/Material Provisioning Committee (MPC)

PC/MPC meetings should be held regularly at the Divisions, at least once every week, with all
members present. Head of Division may review/issue necessary directives to ensure
compliance. The
PC/MPC to be chaired by Head of Division with Head of Planning, Head of Finance, Head of
Quality,
Head of Design liaison, Head of IMM as members and Head of Purchase as member secretary
for PC
and Head of Material Planning/user for MPC. Other members can be co-opted on need basis.
Registration of Purchase Requests: All Purchase Requests shall be centrally registered in the
Purchase Department in the Purchase Request Progression Register/Database.
 DAY 11 29/05/18
FINANCE

Vision and Mission

Vision

1. Promote people’s ownership of Central Public Sector Enterprises to share in their

prosperity through disinvestment.
2. Efficient management of public investment in CPSEs for accelerating economic
development and augmenting Government’s resources for higher expenditure

Mission

1. List CPSEs on stock exchanges to promote people’s ownership through public

participation and improving efficiencies of CPSEs through accountability to its
shareholders.
2. To bring in operational efficiencies in CPSEs through strategic investment, ensuring their
greater contribution to economy.
3. Adopt a professional approach for financial management of CPSEs in the national
interest and investment aimed at expanding public participation in ownership of CPSEs.

HAL FINANCIAL PERSPECTIVE

Hindustan Aeronautics Limited is a large manufacturing organization
a n d i t s m a i n customers is Indian Air Force which gives HAL various orders for
manufacturing, repairs a n d o v e r h a u l , d e s i g n a n d d e v e l o p m e n t e t c . a n d
p r o v i d e s 9 0 % a m o u n t o f o r d e r i n g i n advance and rest 10% after receiving
the complete order, so in this way HAL realizes 90% ordering amount before the supply
of the items and only 10% of the amount blocks. Therefore, the need of working capital
in case of HAL is not much high with respect to other manufacturing
organizations. HAL has civil customers and it also takes contracts from Navy and
Coast Guard, Aeronautical Development agency (ADA) etc. The projects undertaken by HAL
are either company financed or customer financed. It takes money from
customers in advance for the functioning of the projects. Company also finances
some of the projects and in these cases funds are provided by the government.
Company does not suffers from losses because there is no risk in the investment of projects
because investment is made on the basis of orders and some percentage of total
amount of the project is provided to the company in advance to start the projects. The
organization has its Corporate Office in Bangalore; all the financial activities are
controlled from the corporate office. Since it is a major manufacturing company
of the g o v e r n m e n t t h e r e f o r e n o i n v e s t m e n t p o l i c y i s b e i n g f o l l o w e d b y i t
a t A c c e s s o r i e s Division, Lucknow. Capital structure theories are not applied by this
organization because being a Pub lic Sector Unit; its main power is in the hands of
government.
BIBILIOGRAPHY

1) HAL process manuals

2) Wikipedia