|PAC – Pakistan Aeronautical Complex
The conception of idea to establish Pakistan Aeronautical Complex dates back to the early seventies. The rationale behind this idea was both economic and strategic. The aim before the policy makers was to create an indigenous production facility in which aircraft and engines could be overhauled and repaired without sending them abroad and doling out large sums of foreign exchange. Later years saw expansion in the role of PAC in terms of aircraft and engines production, upgrade programmes and joint ventures.
Since inauguration of the first of its four factories in 1978, Pakistan Aeronautical Complex has not looked back. In the two decades, it has vastly expanded the scope of work, commenced new and more challenging projects, created a veritable centre of excellence in military aviation and information technology, and above all, realised the original goal of self-reliance. Eversince its inception, Pakistan Aeronautical Complex has become the backbone of Pakistan Air Force in maintenance; supporting its major weapon systems by providing rebuild services for aircraft, engines and components; providing spare support, structural repairs and major rectification. Manufacture of Mushshak aircraft and collobaration with China in K-8 jet trainer programme are landmark achievements of PAC which have lent tremendous creditability to this industry. More recently PAC has also ventured into the area of system upgrades and manufacture of airborne avionics systems in partnership with some foreign collobarations. Having acquired necessary resources and expertise. PAC is fast expanding its role and making all-out efforts to turn itself into a self-supporting outfit. Already, it is ensuring that the country spends least amount of foreign exchange on maintenance of the PAF fleet of fighter and trainer aircraft. Except for import of certain essential spares, rest everything is produced or repaired locally.
In PAC, quality of products and services occupies the fundamental importance. Quality received tremendous boost recently when the four factories of this complex were certified to ISO-9000 quality management system by the leading international auditing firms. This has enormously enhanced the prestige and the credentials of this complex with the aviation circles around the world. They now consider us serious contenders for joint ventures and partnerships. With this, PAC is now committed to a standard which can neither be lowered nor compromised in future.
DIRECTOR GENERAL: Air Vice Marshal A. Rahim Yousefzai
Pakistan Aeronautical Complex is an organ of Pakistan Ministry of Defence; consists of four factories, as follows:
F-6 REBUILD FACTORY (F-6 RF): Established in 1980 primarily for overhauling Pakistan’s Shenyang F-6s and their accessories; has expanded its role by undertaking overhaul of F-6, FT-6, A-5III, FT-5 and F-7P aircraft along with its components and accessories. FT-7P aircraft and accessories overhaul programme has recently commenced production.
F-6 RF authorised to manufacture over 11,000 spares parts for F-6/FT-6, A-5III/FT-5 and F-7P aircraft and production of 500 and 800 litre (132 and 211 US gallon; 110 and 176 Imp gallon) supersonic drop tanks for F-7P; 1997 workforce approximately 2,700. F-6 RF possesses modern technical facilities for various engineering processes such as guns overhauling, surface treatment, heat treatment, forging, casting, non-destructive testing, canopy bubble forming and machine tools required to manufacture items from raw materials. Both conventional as well as modern machines such as CNC lathe, CNC machining centre, EDM die-sinking and EDM wire-cutting are utilised for various engineering processes. Precision casting facility and advanced metrological centre have been recently established.
In February 1997, F-6 RF was certified to the ISO 9002 Quality Management System.
MIRAGE REBUILD FACTORY (MRF): Began operating in 1978; has site area of 249 acres, approximately 1,600 engineers and technicians; can accomplish complete overhaul of Mirage III/5, ATAR 09C engine, and all associated aircraft components and engine accessories; can overhaul/rebuild third country Mirage III/5s, engines, components and accessories; has overhauled eight United Arab Emirates Air Force Mirages and 42 Dassault/Commonwealth Mirage IIIOAs and eight IIIDs, bought from Australia in 1991. Structural repair facility for Mirage fuselage and wings has been established. Facilities are now fully upgraded to undertake Increased Life Core (ILC) modification, overhaul and upgrade of Pratt & Whitney F100-PW-200E turbofans and F-16 engine jet fuel starters. The limited capability to service and overhaul F-100 engine accessories has also been established.
On 14 September 1995, MRF was officially notified of being awarded certification to ISO 9002 standard. MRF is the first defence organisation in Pakistan to gain certification to the International ISO 9000 Series of Quality Management Systems. KAMRA AVIONICS AND RADAR FACTORY (KARF): Began operating 1987; employs over 250 engineers and technicians. At present rebuilding Siemens MPDR-45E radars, complex components and electronics modules, and caterpillar/Siemens power generators. Has modern, environmentally controlled and ASD equipped electronics workshops, environmental test chambers, sophisticated test measurement, and Pagamat ATE diagnostic equipment. Shortly to undertake rebuilding of Siemens control and reporting centre and MPDR-60/90 radars. Involved in co-production of airborne radar for fighters and upgrading of Mirage III avionics suite.
Kamra Avionics & Radar Factory (KARF): RWR BM/KJ 8602 system is designed to provide the pilot with real time and unambiguous threat warning over 360 degrees thus reducing vulnerability of the combat aircraft to radar associated weapons. Automatic sorting and identification of threat emissions are provided. The system can operate in conjunction with ECM units and chaff / flare dispensers for self protection of the aircraft. The production facility was established with Chinese collaboration and is capable of complete assembling ,testing and depot level repair of RWR equipment. This facility consists of an electrical assembly line for fabrication , stuffing , soldering , wiring and looms / harness fabrication. The alignment and testing line has the facilities for VSWR measurement and Special-to-type testing. After a complete system has been produced , its integration , software programming , aging and lacquering are performed in a system alignment room. The real field RF measurements are carried out in a system test room which has an anechoic chamber . The system produced is tested for vibration , impact , bump and ‘G’ effects. Availability of elaborate environmental test chambers enable high and low temperature , humidity and burn-in testing .
The Grifo-7 radar is a coherent digital fire control system designed to improve air to air and air to ground performances of F-7P aircraft. It is designed to fit into aircraft nose bay by replacing the existing ranging radar and to interface the operator via HUDWAC with an improved software configuration. The radar provides an Air Combat Mode with two different acquisition modes namely boresight and super search. The doppler processing of both the modes allows target detection and track at all the altitudes in lookup/look down geometry. The radar provides an Air to Ground Ranging mode to support the Continuously Computed Impact Point (CCIP) attack by supplying the HUDWAC the altitudes above ground to the point where antenna is looking. The digital signal processing and digital radar control improves the radar reliability and the ease of maintenance by auto calibration and Build-in Test (BIT) functionality with minimum pilot workload. Moreover special hot plates for PCB preheating, heating and drying ovens with maximum temperature of 300 degrees celsius, and pneumatic press are also available.
After the disassembly of the electronic equipment of radar and CRC, sub-assemblies are worked upon in their specialized shops. The inspection of each LRU/module is carried out according to international specifications by injecting stimuli and then monitoring their responses. These shops are equipped with sophisticated PME which enables component level repair/testing of line replaceable units (LRUs). Special efforts are made to ensure dust free environment in the shops. To achieve high quality , reliability and ensure customer satisfaction, all the production activities are carried out in large, spaciously built shops equipped with state-of-the-art production machinery. The shops provide suitable environmentally controlled conditions required for the specific jobs being carried out in particular work areas. Every effort is made to restore original specifications, in case of rebuild, as well as in manufacturing as laid down by the original equipment manufacturer
Pegamat is an Automated Test Equipment (ATE) used to test the digital cards of MPDR and CRC Systems. It has the capability to simulate the inputs to digital PCBs and then to compare the output, thereby enabling the technicians to carry out component level repair of all types of digital PCBs. All assemblies which lie in microwave region needs inspection/ testing. These inspections/ testing are carried out in the Microwave Shop which is equipped with advanced RF test and diagnostic equipment including scalar network analyzers, signal generators, spectrum analyzers etc. The shop is also having software controlled microwave test set up, indigenously developed by KARF. Shop facilities established at the Microwave Shop are unique in the country and can handle all types of RF switches, feeds, filters, amplifiers etc.
KARF has the complete capability to test, inspect and repair all types of data, power and RF cables. During the rebuild process of MPDR/ CRC , all the cables are tested and inspected in this shop. All types of connectors are available and to ensure the long life of cable, heat shrinkable sleeves of all required sizes are used extensively to repair the insulation. Similarly the connectors are also replaced to ensure confirmed connectivities. Radars and the CRCs are subjected to complete functional check using the master system. The systems are operated in real environment to ensure reliability of their operation and serviceability.
The mechanical systems of the MPDR and CRC are overhauled and rebuilt after testing as per the manufacturers specifications. Antenna Pedestal Shop is capable of complete rebuild/alignment of antenna pedestal and its associated parts like Synchro bridges and gear case motor. Synchro bridge is made up of precision gears and synchros which convert the circular motion of antenna reflector into electrical signals. All types of synchro gears are tested on Gear Testing Machine with the help of master gears. Synchro bridge is tested / aligned with the help of Antenna Test Set.
KARF has complete rebuild facility for three-phase air conditioners which are used in radars as well as in the CRC. Each air conditioner is disassembled into different parts like condenser, compressor, evaporator, fan motor etc. All these parts undergo necessary rebuild. After this, the air conditioners are assembled and gas charging is carried out by using highly sophisticated gas charging station. After rebuild, each air conditioner is given functional run of 18 hours and a quality check by quality inspector. Finally, the air conditioner is installed on the radar where it is tested in field conditions. Various work bays exist for the rebuild of the components and sub-systems of air conditioners. This facility can cater for all types of commercial air conditioners as well. Hydraulic and mechanical shop has the complete facility for testing hydraulic cylinders, pumps, multiway valves, switches and other hydraulic components. It is capable of carrying out a complete rebuild of Hinged Mast and its associated parts. The workmanship, serviceability and reliability of hydraulic components and system is ensured through simulated testing at test loads that are many times higher than the original.
KARF has a very well equipped machining and welding shop. Conventional lathes, drilling, milling, grinding, sheet bending, sheet cutting, horizontal boring machines and welding of different types are available at this Shop. Skilled manpower and good quality machines combined together ensures high standard work on radar mechanical parts.
The roots of Air Weapons Complex (AWC) extend to 1990. Although it is a young company but that is why it is different. It has energy and dynamism which hard to match. AWC’s foundations were laid by the Government and it offers the most diverse range of products and services in the region to achieve self reliance in the Aerospace and Defence industry. Our efforts are boosted by the nation’s desire to score excellent and perfection in the high technology field thus establishing the foundations to emerge as a developed nation in the 21st century.
Our Corporate Objective is to utilize and develop local vendor industry to its maximum potential thus contributing not only towards national development but also helping to build a perfect infrastructure for the industries which is a great incentive for foreign investors. To dedicate our efforts not only for national development but also provide services at international level. One of the company’s principle avenues of business development is to establish working relationships with foreign companies who wish to enter technology transfer agreements or other joint venture / co-development / co-production arrangements.
Our goals has been to provide a progressive response to ongoing development in the world and to fulfill today’s technical needs with tomorrow in mind. To renew ourselves and our production capabilities by updated technologies. Our services are just part of an on-going and uncompromising search for excellence aimed at putting ourselves, and our clients in the forefront of the emerging technologies of today and tomorrow. This kind of commitment has been achieved by AWC nurturing an atmosphere where invention and excellence are prized and respected. For AWC, this attitude has helped to create a precious, integrated and high tech facility.
Our visions are imperative and our today’s decisions will have a major effect on what reality will look like in the 21st century. And it is immaculately this commitment that reigns at AWC. We are setting all our technological capabilities in motion to see that vision become reality. Day in and day out we are applying this concentration of high-tech know-how to make vision become reality, for humanity and its future.