`The Knowledge and Experience We Gained Through C-Level Overhaul Procedures for A400M Aircraft in Turkey is Invaluable!`
Defence Turkey: Can we start our interview with a brief history of the 2nd Air Maintenance Factory Directorate (2nd AMFD), which dates back to 1926?
Brig. Gen. Haldun TAŞAN: One of the first steps taken for the development of Turkish industry in the first years of the Republic was establishing an aircraft factory in Kayseri. Our factory was built on the foundations laid on an empty area with materials transported from Mersin Port by sea and overland by mules. As Turkey's first aircraft factory, it was established in 1926 under "Aircraft Factory" with the partnership of the Turkish Aeroplane League and German Junkers Company. Five engineers and 120 German and 240 Turkish workers started to work at the facility during its establishment. In about ten years, license agreements were signed with companies from Germany, the USA, England, and Poland, and a total of 134 aircraft in 5 different types and 50 gliders were manufactured. With the cooperation established at that time, the production of "Fighter Aircraft" was also started. German Junkers aircraft and Curtiss Hawk are the best examples of these collaborations. In addition, Depot-Level Maintenance and Repair of 24 different aircraft types and overhauls of 14 types of engines were carried out between 1937 and 1947. Our factory has been operating under the name of the 2nd Air Maintenance Factory Directorate since the organizational change in 2017.
Defence Turkey: What can you tell us about the indoor and outdoor area size of the 2nd AMFD facilities, the number of FASBAT (Depot-Level Maintenance and Repair) workshops and hangars, and the annual capacity?
Brig. Gen. Haldun TAŞAN: The 2nd AMFD facilities are located on an area of more than 4,000 acres with 463 buildings. It can perform Depot-Level Maintenance and Repair of approximately 30 aircraft per year.
Defence Turkey: Can we get information about the duties and responsibilities of the 2nd Air Maintenance Factory Directorate, its organizational structure, and the services you provide?
Brig. Gen. Haldun TAŞAN: Continuing its activities under the Ministry of National Defense General Directorate of Military Factories; the 2nd AMFD consists of Aircraft D-Level Maintenance Directorate, Ground Systems Directorate, Manufacturing Workshops Directorate, and Technical Management Presidency sub-units. The number of our engineers and workers is over 1,000. We provide depot-level maintenance and repair services for transport aircraft, turboprop trainer aircraft, ground systems, and manufacturing of needed systems, equipment, and materials. In addition, we have assumed the responsibility of technical management, which covers all the engineering activities throughout the lifecycle of aircraft and ground systems.
Defence Turkey: What can you tell us about the services you offer and your product range as part of your Depot-Level Maintenance and Repair activities?
Brig. Gen. Haldun TAŞAN: We provide D-level maintenance and repair for T-41, SF-260D, CN-235, C-130, C-160, KC-135R, and A400M Aircraft and ground systems such as emergency arresting systems, aircraft starters, generators, and fueler vehicles. Our production capabilities include aircraft towing vehicles, bomb loaders, parachutes, and other equipment.
Defence Turkey: Could you enlighten our readers about your Aircraft Maintenance, Repair, and Overhaul (MRO) capabilities? In this context, which type of aircraft do you offer services for?
Brig. Gen. Haldun TAŞAN: We have unit repair capabilities for T-41, SF-260D, CN-235, C-130, C-160, KC-135R, and A400M Aircraft as well as F-4 and F-16 Aircraft. Our unit repair catalog includes approximately 6,000 products such as propellers, landing gear, piston (reciprocating) engines, generators, pumps, and avionics systems. Our repair capacity has increased up to 10,000 units per year.
Defence Turkey: What kind of services do you offer for Unmanned Aerial Vehicles?
Brig. Gen. Haldun TAŞAN: We provide engineering services for Unmanned Aerial Vehicles in the inventory of the Turkish Air Force Command. When required, we also carry out manufacturing, repair, and overhaul activities within our factory.
Defence Turkey: What can you tell us about the latest situation regarding the Seyit Onbaşı Bomb Loading Vehicle, MJ-1TR Bomb Loader, Koca Yusuf-2 Bomb Loading Vehicle, and Rahvan Aircraft Towing Vehicle Projects, which went into serial production in 2014?
Brig. Gen. Haldun TAŞAN: The modernization of the existing MJ-1 Bomb Loaders was completed in 2016, and the service life of the devices was extended thanks to this project. With the Seyit Onbaşı (Kocayusuf-2) Project, we aimed to design, manufacture and maintain bomb loading vehicles with domestic capabilities. Our goal was to produce 70 "Seyit Onbaşı Bomb Loading Vehicles." We have completed the production of 34 vehicles, and we will deliver the rest within the program's framework. The Rahvan Aircraft Towing Vehicle Manufacturing Project aimed to manufacture an indigenously designed aircraft towing vehicle. In this context, we have completed the production of 90 vehicles. The vehicle has a 60,000 kg (133,000 lbs.) towing capacity, domestic diesel engine, four-wheel (4x4) drive, and high maneuverability thanks to its front and rear-axle steering. In addition, we have completed the development of prototypes for the mass production of 47 more units, and the mass production process has been started as of this year. Thus, we have gained the capability to manufacture domestic Aircraft Towing Vehicles. Thanks to localization, both of our projects increased the effectiveness of supportability activities and contributed to our national budget.
Defence Turkey: Can we get information about the manufacturing activities and technologies used in the 2nd AMFD facilities?
Brig. Gen. Haldun TAŞAN: We can explain our maintenance activities for the weapon systems under our responsibility and our manufacturing capabilities for the needs of the Turkish Air Force under six main categories.
These technologies are:
Machining (Turning-Milling-Grinding),
Sheet Metal Fabrication & Assembly (Cutting-Bending-Pressing-Assembly-Pipe/Hose),
Heat Treating (Welding-Heat Treatment-Casting-Forging),
Surface Preparation (Coating-Paint-Sandblasting),
Composite Technologies (Tire-Thermoplastics-Ballistic-Vacuum),
Fabric manufacturing (Parachute-Polyester Based Fabrics, the only parachute production center in the Air Force).
In these technology groups, we can produce around 300,000 parts for approximately 2,000 different items per year. The number of items in our material manufacturing catalog has nearing 18,000. Our unit is the manufacturing center with the largest capacity within the Turkish Air Force.
Regarding complete units and spare parts manufacturing capability, we produce:
Aircraft Structural Parts,
Flight Mission Equipment,
Sealing Elements (the only sealing element production center in the TurAF),
Brake, Personnel and Cargo Parachutes (such as T-10B, T-10R, T-16, BA-22, CP-47),
Ground Support Equipment (such as bomb loading vehicles [Seyit Onbaşı], aircraft towing vehicles [Rahvan], aircraft tow bars),
Composite Parts.
Defence Turkey: What can you tell us about your activities and annual capacity for aircraft engines?
Brig. Gen. Haldun TAŞAN: We carry out maintenance, repair, and overhaul activities only for piston aircraft engines. These are Lycoming and Continental piston engines of T-41 and SF-260D Aircraft. Our annual capacity is 18 engines.
Defence Turkey: Depot-level maintenance of the Turkish Air Force (TurAF) C-130 Hercules Aircraft is carried out at the 2nd AMFD facilities. The 2nd AMFD, which also takes part in the ERCIYES Project as the authorized maintenance center of Lockheed Martin, also provides maintenance services to C-130 aircraft of friendly and allied countries. What can you tell us about the countries and the number of aircraft that have been provided with maintenance services in this context during the past period?
Brig. Gen. Haldun TAŞAN: The 2nd AMFD has been performing Depot-Level Maintenance of C-130 Aircraft since 1968. We continue our efforts to renew the Authorized Service Center Certification obtained from Lockheed Martin in 2009. ASFAT continues negotiations on using the existing knowledge and experience in the maintenance of C-130 aircraft for the aircraft of other allied countries. Our feasibility study on the subject has been prepared. We expect the necessary investments to be made and significant developments in the near future.
Defence Turkey: Certified by Airbus Defence & Space (ADS), the 2nd AMFD was awarded a 'Regional Support and Maintenance Center' certificate for CN-235 Aircraft in Turkey and its region at a ceremony held on July 1, 2015. What can you tell us about the scope/level of maintenance and repair services for CN-235 Aircraft at the Factory, man-hours spent per plane, and annual capacity? It was previously stated that VB-3 maintenance checks for CN-235 Aircraft could be carried out at the 2nd AMFD facilities.
Brig. Gen. Haldun TAŞAN: Turkey currently operates the largest CN-235 fleet. Depot-Level Maintenance of CN-235 Aircraft is carried out in our factory in approximately 60 workdays. With our current capacity, we can maintain 8 CN-235 Aircraft per year. We are also responsible for the technical management of CN-235 Aircraft in the inventory of the Turkish Land Forces, Navy, and Air Force. The 2nd AMFD initiated the "Avionics Modernization Project" to increase the flight safety of CN-235 Aircraft and provide these aircraft with capabilities such as TCAS, IFF Mod 5S, ADSB-OUT, and GPS-based Navigation dictated by international air traffic regulations. Test flights were completed with the prototype aircraft. Serial production studies have been started to implement the design to all aircraft. The Regional Support and Maintenance Center studies could not be concluded in 2015 because the avionics modernization was carried out at the 2nd AMFD.
Defence Turkey: Have you ever provided maintenance/repair services for CN-235 Aircraft to any friendly and allied countries? Do you have any ongoing work on sales of maintenance/repair services?
Brig. Gen. Haldun TAŞAN: While the 2nd AMFD does not provide any services to friendly and allied countries, within the scope of the feasibility study carried out recently, investment evaluation is on ASFAT's agenda.
Defence Turkey: Within the scope of the A400M Program, Turkish Air Force personnel would be responsible for the complete Line Maintenance (Level 1) of aircraft as part of the In-Service Support (ISS) concept and maintenance workshops for various subcomponents/subsystems of the aircraft, such as the engines and tires, which would be established within the 12th Air Transport Main Base in Kayseri. On the other hand, a company called Airbus Military Turkey (AMTR, now Airbus DS Turkey) was established in cooperation with TUSAŞ and ADS to provide In-Service Support (ISS) to other users who will own A400Ms in the future, as well as to the A400Ms that will enter service with the Turkish Air Force. Airbus DS Turkey, which started its operations in 2013 with the 100% participation of ADS, would provide complete logistics support for the Turkish Air Force A400M Planes, including aircraft maintenance, by utilizing the capabilities of Air Maintenance Factories, Turkish Technic, and other domestic industry. Meanwhile, Turkish Technic signed an agreement with ADS in May 2015 to provide maintenance support for A400M Aircraft. In this context, what can you tell us about the cooperation between Airbus DS Turkey, Turkish Technic, and the 2nd AMFD and the results of this cooperation?
Brig. Gen. Haldun TAŞAN: Currently, we do not have any cooperation with Turkish Technic on A400M Aircraft. The 2nd AMFD carries out all the maintenance activities required for the A400M Aircraft. Within the scope of A400M Line Maintenance Activities, Airbus DS Turkey provides maintenance, CAMO, and material management support to the 12th Air Transport Main Base under the Global Support Service 2 agreement.
Defence Turkey: Located at the 12th Air Transport Main Base, the 2nd AMFD was certified by ADS to provide C-Level Overhaul service for A400M Aircraft after a year-long inspection and was presented with a certificate at a ceremony held in February 2018. Can we get some information about the scope of the C-Level Overhaul service, the man/hours spent per aircraft, and its importance? How many A400M Aircraft have received C-Level Overhaul at the 2nd AMFD facilities to date?
Brig. Gen. Haldun TAŞAN: The 2nd AMFD carried out eight CL (Intermediate Level) and two CH (Depot Level) maintenance of the A400M Aircraft since 2017. These maintenance periods are 24 months for C1-L, 48 months for C2-L, 96 months for C3-L, and 144 months for C2-H. Of these, CL maintenance is completed in 45 workdays, and CH maintenance is done in 75 workdays. The maintenance is in EMAR-145 standards, and our personnel has A400M type certificate.
Defence Turkey: In previous years, Ministry of National Defense officials stated that Turkey saved EUR 900,000 per aircraft by performing the C-Level Overhaul operations of the A400M Aircraft at the 2nd AMFD facilities, and the maintenance operations that took six months abroad could be completed in about two months in Turkey. Can we get some information on how much is saved by performing the C-Level Overhauls in Turkey?
Brig. Gen. Haldun TAŞAN: When we compare the maintenance performed by the 2nd AMFD with the other centers abroad in terms of time and cost, we see that there is a significant saving. CL maintenance, which costs around EUR 900,000 abroad, can be met with much lower costs in the country. In this context, the value of the knowledge and experience we have gained is invaluable.
Defence Turkey: According to the information shared before, the 2nd AMFD also gains significant experience with this project for CH Level maintenance that will be carried out 12 years later. Could you enlighten our readers about the scope of CH Level maintenance?
Brig. Gen. Haldun TAŞAN: CH is a Depot-Level maintenance. In this maintenance package, nearly 1,000 panels and covers are removed from the aircraft. The 2nd AMFD is the first maintenance center outside the Airbus facilities to carry out the CH package, which includes controls and tests for all systems on the aircraft. The activities were completed in less than four months.
Defence Turkey: The A400M Aircraft Maintenance-Repair-Retrofit Contract was signed between ADS and ASFAT at a ceremony held on October 3, 2019. With the contract, the 2nd AMFD gained the capability to provide retrofit services not only for the A400M Aircraft in the Turkish Air Force inventory but also for the A400M Aircraft in the service of friendly and allied countries in the region. What can you tell us about the scope of the retrofit, which is stated to be carried out at the 2nd AMFD for the first time outside of Spain, the man/hours to be spent per aircraft, and how much will be saved by carrying out this operation with national capabilities?
Brig. Gen. Haldun TAŞAN: By definition, 'retrofit' is the addition of new features based on the user feedback and design changes introduced after the commissioning of the A400M Aircraft at a later period when the plane enters the version upgrade program. The 2nd AMFD is the only maintenance center outside Airbus facilities that can perform the retrofit process. We started our first retrofit activity on December 7, 2020 and completed it on July 30, 2021. The retrofit work can be grouped under three main categories as structural operations, aircraft Harness operations, and intensive software operations.
On our first aircraft, we carried out these retrofit operations:
Improved Ramp Aerial Delivery System (RAS),
Nighttime Airborne Operation capability,
Improved DASS (Defensive Aids Sub-System) System,
Automatic low-level flight, performing tactical missions at low altitudes with the autopilot,
Upgrading the loading crane to full capacity,
Using the on-board oxygen generating system (OBOGS) at full capacity – Unlimited oxygen production capability,
Increased cargo section storage area.
Thanks to the retrofit activities carried out in our factory; we save approximately EUR 1,000,000 per aircraft. In addition, the capabilities we have gained are invaluable. As a matter of fact, we aim to transfer our increasing international technical know-how to different fields. Furthermore, we have made significant contributions by shortening the retrofit time. Thus, we have extended the time our planes can stay in the air even more.
Defence Turkey: Previously, in 2015-2016, two A400M Aircraft were retrofitted at ADS facilities in Getafe, Spain. ADS officials we interviewed stated that with this retrofit work, which mainly covers hardware and software, including the engines, the planes were upgraded to the latest configuration. Will the retrofit work to be carried out at the 2nd AMFD be similar to the work in Spain? In this context, what kind of cooperation was established with ADS? What kind of technical/hardware support will be provided from there?
Brig. Gen. Haldun TAŞAN: Ongoing and planned retrofit work packages are provided by Airbus. We do not receive any technical support from Airbus during the implementation. A limited number of Airbus representatives observe and advise on the ground. Retrofit work in Spain also included software and structural upgrades. The current work package does not include engine-related improvements. However, we consider that engine retrofits can also be performed in Kayseri as part of our planned studies. We are currently discussing this issue with Airbus.
Defence Turkey: As far as we know, the retrofit processes on the first A400M Aircraft in Air Force service started in December 2020, and it was announced that the work would be completed in July 2021. Can we get information about the latest situation in the retrofit work?
Brig. Gen. Haldun TAŞAN: As of July 30, 2021, the first retrofitted aircraft has been delivered to the Air Force with all necessary service bulletins applied. All operations were carried out by A400M type trained personnel of the 2nd Air Maintenance Factory Directorate, meeting all EMAR-145 requirements.
Defence Turkey: Is the maintenance-repair-retrofit work level the same on every plane? As far as we know, A400M Planes were delivered in different configurations, and software updates were gradually installed later. For example, the last A400Ms delivered to the Turkish Air Force were at the Batch 4 level.
Brig. Gen. Haldun TAŞAN: No. Each plane's retrofit package will be different from the other. For example, the work package to be implemented during the retrofit of the following aircraft could be more comprehensive than our current aircraft. Software version upgrades are prioritized. We expect the entire package to be completed in approximately seven months.
Defence Turkey: What can you share about your activities or capabilities for the TP400-D6 turboprop engines of A400M Aircraft? Deliveries of Pack-2 engines started in recent years. Will the 2nd AMFD play a role in upgrading the engines on the A400M Aircraft in TurAF service to Pack-2 Level?
Brig. Gen. Haldun TAŞAN: The 2nd AMFD can perform Unit Level Maintenance for TP400-D6 engines. Borescope inspection and replacement of certain parts and units are also among our capabilities. The 2nd AMFD will not play an active role in upgrading the A400M engines to the Pack-2 Level, except for removing and installing the engines, PGB, and engine equipment. We will provide personnel and technical support and perform quality control stages when necessary. However, we are also working to gain maintenance, repair, and overhaul capability, especially for propellers and systems in the future.
Defence Turkey: Is there anything you would like to add as a message to our readers?
Brig. Gen. Haldun TAŞAN: Finally, as the 2nd AMFD, our efforts continue to carry out the maintenance and repair of all weapon systems assigned to our responsibility at world standards. Especially for military cargo planes, we are becoming an international maintenance center with our organization, personnel, facilities, and equipment. We continue our efforts to contribute to both the regional and national economies with the service we provide to the aircraft in our inventory and to the planes of other allied countries.
Defence Turkey: General, thank you for your time, and we wish you success in your work.
