Airbus Helicopters’ Grand Prairie, Texas facility has taken a major step forward in improving dynamic component repair (DCR) with the certification of a new multi-purpose test bench in late 2024. This advancement is set to enhance customer support, reduce turnaround times (TATs), and boost efficiency.
A Critical Function
DCR focuses on repairing vital helicopter components, including main and tail rotor gearboxes and shafts, which are essential for flight safety and performance. In the Grand Prairie workshop, about 1,000 components undergo servicing annually—80% scheduled overhauls and 20% unscheduled repairs—with 200 major components like main gearboxes requiring intensive work.
Sebastien Mathiot, Senior Manager of Dynamic Component MRO, acknowledges that delays can sometimes arise due to supply chain challenges and increased workload from military programmes. However, a structured overhaul of the repair process has already shown significant improvements.
Scaling Up for Efficiency
To meet growing demand, the facility has expanded by 50%, and its workforce has tripled in size over four years. Investment in Visual Dimensional Inspection (VDI) and Non-Destructive Inspection (NDI) has set a new industry benchmark, ensuring greater reliability and efficiency.
The DCR test bench, now fully qualified and certified, is a game-changer. It allows for full load testing of key components by simulating real-world helicopter conditions, measuring torque, power, vibrations, flow, and temperature. Already in use for H135, AS365, and H145 main gearboxes, it is also future-ready for the H160.
More to Come
While turnaround times have already improved—25% faster for large components and over 45% faster for smaller components—Airbus Helicopters is not stopping here.
Vice President of Customer Support & Services in North America, Niko Szodruch, emphasises that while progress has been made, major component repairs remain a priority. Future investments include:
- A three-axis milling machine and computerised numerically controlled machining centre to increase on-site repair capabilities.
- Further digitisation to enhance transparency and communication with customers.
“This transformation has taken incredible collaboration between many teams,” says Szodruch. “Every single initiative is a brick in building a stronger, more efficient operation.”
As Airbus Helicopters continues to overhaul the overhaul, customers can expect faster, more reliable service, ensuring helicopters spend less time in repair and more time in the skies.
SOURCE AND IMAGE©: AIRBUS
