GE F-404 Engine Shortage Stalls Tejas Mk1A Production at HAL's Nashik Facility

Hindustan Aeronautics Limited (HAL), the primary manufacturer of India's Tejas Light Combat Aircraft (LCA), is facing significant production delays for the Tejas Mk1A due to a shortage of F-404 engines from GE Aerospace.

This setback has impacted the planned rollout of the first Tejas Mk1A jet from HAL's new production line in Nashik, pushing the milestone from November 2024 to March 2025.

HAL currently produces 16 Tejas LCA aircraft per year at its two facilities in Bangalore. The Nashik facility, intended to boost production capacity with an initial output of five Tejas Mk1A jets annually (eventually increasing to eight), is now facing hurdles due to the engine shortage. This delay directly affects HAL's ability to meet the Indian Air Force's (IAF) order of 83 Tejas Mk1A jets, a contract worth ₹46,898 crore signed in February 2021.

The F-404 engine, manufactured by GE Aerospace, is the powerplant for the Tejas Mk1A. GE Aerospace has attributed the supply delay to global supply chain disruptions impacting the aerospace industry. This shortage affects not only the production of new aircraft but also the maintenance and upgrade of existing Tejas aircraft requiring engine replacements or overhauls.

This delay raises concerns about HAL's ability to meet its delivery schedule for the Tejas Mk1A, a crucial component of the IAF's modernization plans. The Nashik facility was expected to alleviate pressure on existing production lines and expedite deliveries. However, the engine supply bottleneck has stalled these efforts.

 

[Pratimesh Singh]

At this point I just feel bad for the IAF. And what is the government doing just waiting day by day so that our squadron strength decreases. They should have started getting aircrafts under MMRCA by now. But as usual so slow process.

 

[Chandrasekar Raghupathy]

I still say India is in big trouble.

We will get F404, F414 (TOT) only if we buy MRFA aircrafts, Stryker, MQ9 etc from USA.

America is taking advantage of India's current situation. The US is taking advantage of the fact that India is in a position to strengthen its air force after seeing the air forces of Pakistan and China. We have no choice now.

While we were designing aircraft like Tejas, AMCA, TEDBF, America should have designed without engine dependence.

Now if we have to change the design of our planes to suit the French and Russian engines, it will take another ten years.

The same F404 engine is going to countries like South Korea F50, Turkey Hurjet, Sweden JAS39, US Boieng saab Red Hawk and so on

India's current situation is very bad, the design of the aircraft cannot be changed and the engine cannot be changed. Engine and technology will not be available unless we buy American goods..

All that is story now, what are the mitigation plans, start working towards that, stop beating the chest, learn from China how to work on projects

 

[Arvind Sharma]

IAF didn’t choose the engines. ADA chose the engines. They placed orders. And in fact, IAF wanted Kaveri. DRDO failed to make them. Then IAF wanted mk2 but HAL failed to deliver. So they were forced to buy mk1a.

And indeed, that’s the problem. They don’t do the things they are supposed to do.

Because HAL would have kept profit margins even on the engines. They are authorised Mr. Minimum 15%.
Till now HAL has acted just like commission agent.

 

[Muthu.Kumar]

This IS the price to pay for being so lethargic and unwilling to learn from the mistakes after mistakes that we're committing.

First biggest mistake is putting the trust on GE - whis has the history of betrayal and backstabbing in the past.

That too Govt - Govt agreement ?
That too for only 80% TOT, when France offered 100%, giving up the fullest control (IP rights, export control etc.) ??

Can't avoid thinking that something wrong went behind the screen.

Second mistake is the failure to invest in and focus on Kaveri. Granted that past governments pathetically and unforgivably failed, but at least this govt. which is in power for the third term, should've made Kaveri it's priority, by pumping in more funds and bringing in the best and the brightest from the academia (and/or getting some help from abroad on consulting basis) to bring it up as THE engine.

Not sure if there was any plan B in situations like this or was a plan B possible, b/c HAL said that, Tejas was designed to be compatible only with GE engines. Seriously ? I mean, SERIOUSLY ??

At least, AT LEAST FROM NOW ON, I expect the govt. to aggressively push for indigenous R & D. Piggybacking on the others' shoulders only make as intellectually challenged. Then, there's no point in having such premier institutions as IITs, IISc et all.

The very phrase "MAKE In India" is wrong, which should've been "INNOVATIVE/RESEARCH/DESIGN In India", IMHO.

 

[captsai]

This IS the price to pay for being so lethargic and unwilling to learn from the mistakes after mistakes that we're committing.

First biggest mistake is putting the trust on GE - whis has the history of betrayal and backstabbing in the past.

That too Govt - Govt agreement ?
That too for only 80% TOT, when France offered 100%, giving up the fullest control (IP rights, export control etc.) ??

Can't avoid thinking that something wrong went behind the screen.

Second mistake is the failure to invest in and focus on Kaveri. Granted that past governments pathetically and unforgivably failed, but at least this govt. which is in power for the third term, should've made Kaveri it's priority, by pumping in more funds and bringing in the best and the brightest from the academia (and/or getting some help from abroad on consulting basis) to bring it up as THE engine.

Not sure if there was any plan B in situations like this or was a plan B possible, b/c HAL said that, Tejas was designed to be compatible only with GE engines. Seriously ? I mean, SERIOUSLY ??

At least, AT LEAST FROM NOW ON, I expect the govt. to aggressively push for indigenous R & D. Piggybacking on the others' shoulders only make as intellectually challenged. Then, there's no point in having such premier institutions as IITs, IISc et all.

The very phrase "MAKE In India" is wrong, which should've been "INNOVATIVE/RESEARCH/DESIGN In India", IMHO.

Very valid points and true. ADA was created as an autonomous agency to function & take decisions easily with integrated FA to fasttrack policies & contracts.
Unfortunately the decades of Colonial mindset and old loyalties is set into many Indians. Many are swung by foreign visits especially US. DRDO, ADA & Cabinet Committees are the ones who make policies passed by the RM. The PM, FM & RM can create an environment / platforms for ease of doing business by cutting red tape and old licence raj mind sets but people and entire work force right upto management across scientists, defence, ministries & buerocrats have to change and adopt without being subservient which is largely the order that prevails.
Even 2 or more parallel JVs like betwn HAL & Safra, ADA & RR or ADA & GE with full TOT and about 3 assy lines in 2 or more states is what policy makers need to focus on and make happen, given the sheer size and numbers of the needs of IAF / IN / IA & the new world of Drones, UAVs, cross small weaponised UAVs etc

 

[captsai]

High time the NMG (Numerical Master Geometry) of LCA Mk1A, TEDBA, AMCA etc are shared with our select PVT Aerospace agencies like Tatas, Reliance, Adani, Mahendra etc to in turn pursue JVs with aero engine manufacturers and establish MAKE IN INDIA AERO ENGINES