HAL to Establish Fourth Tejas LCA Assembly Line in Nashik to Boost Production Amid Engine Supply Challenges

Hindustan Aeronautics Limited (HAL) is taking a significant step to expedite the production of the Tejas Light Combat Aircraft (LCA) by setting up a fourth assembly line at its Nashik facility. This development comes as a response to delays in the delivery of F-404 engines by General Electric (GE), which has affected the manufacturing timeline for the Tejas Mk-1 fleet. With GE expected to resume engine deliveries by March 2025, HAL is strategically positioning itself to make up for lost time and bolster the Indian Air Force's (IAF) fighter squadron strength.

Addressing Production Delays with Expansion

Currently, HAL operates two LCA assembly lines in Bengaluru, each with the capacity to produce eight aircraft annually. A third assembly line in Nashik, inaugurated recently, is expected to deliver its first Tejas LCA by March 2025. To further accelerate production, HAL plans to establish a fourth assembly line at the same facility, aiming for an additional output of eight aircraft annually. However, the completion of this new line will depend on the timely and consistent supply of F-404 engines from GE. HAL estimates it will require approximately 1.5 years to set up this new production facility.

GE Engine Supply Challenges

The F-404 engine, which powers the Tejas Mk-1, has been a critical bottleneck in the production process. GE is currently grappling with a backlog of 26 engines, causing significant delays. Indian officials, recognizing the importance of these engines for the IAF's operational readiness, have engaged in diplomatic discussions with their US counterparts to address the issue. GE has committed to delivering the first engine by March 2025, with plans to scale up production thereafter.

The Strategic Importance of Tejas LCA

The IAF is currently facing a squadron strength crisis, with only 31 operational squadrons against a sanctioned strength of 42. The impending retirement of the remaining MiG-21 squadrons is likely to exacerbate this shortfall. In response, the Indian government signed a Rs 45,696 crore deal with HAL in 2021 for 83 Tejas Mk-1A aircraft (73 fighters and 10 trainers). The timely production of these aircraft is critical for maintaining India's air superiority and meeting the operational requirements of the IAF.

Recent Progress and Future Prospects

Despite the delays, HAL has made progress by assembling the first Tejas Mk-1A using reserve engines. This aircraft is currently undergoing trials and is expected to be showcased at Aero India 2025. The second Mk-1A is already on the assembly line, demonstrating HAL's commitment to overcoming challenges and maintaining production momentum.

The establishment of a fourth assembly line, coupled with the resumption of engine deliveries, is poised to significantly enhance HAL’s production capabilities. This expansion will not only support the IAF's modernization efforts but also strengthen India's indigenous defense manufacturing sector, aligning with the government's "Make in India" initiative.

As HAL gears up to ramp up production, the Tejas LCA program stands as a testament to India's engineering and defense capabilities, ensuring a robust and agile response to evolving security challenges.