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BILLION DOLLAR OPPORTUNITIES IN THE INDIAN DEFENCE SECTOR
Dr VK SaraswatDAE Homi Bhabha Chair
Former Secretary Dept of Defence R&D; Scientific Adviser to Raksha Mantri and
Director General DRDO & ADA
Conference on Defenceby Edelweiss Securities Ltd, Mumbai
On18 Jul 2014
Development & Production Culture1960-2010
Indian Defence Industry (Govt & Public)Product Profile
No. of Factories : 39 + 2 Principal Items - 881Manpower : 99000 (approx) Anti Tank Guns, Field Guns, Mortars, Small Arms, Bombs,
Rockets, Grenades, Mines, Depth Charge, Explosives, Propellants, Pyro Technique Stores, Transport Vehicles, Optical and Fire Control Instruments, Bridges,Assault Boats, Clothing / Protection Suits, Parachutes
HAL(19 Div)
BEL(9 Div)
BEML(4 Div)
BDL(3 Div)
SHIPYARDS(4 Units)
MIDHANI(1 Div)
Sale Rs.1,43,230
Cr
Sale Rs.6,012 Cr
Sale Rs.3,290 Cr
Sale Rs.475 Cr
Sale Rs.2,798 Cr
Sale Rs.2,424 Cr
Aircrafts Radars Mining / Construction Eqpt
Missiles Ships Super Alloys Prodn
Helicopters Communication
Rail / Metro Products
Torpedoes Submarines Titanium Spl.Purpose Steel
UAV EW Systems Wheeled Vehicles
Launchers Boats Turnover Rs.510 Cr
Radars Elect/Opt Systems
Decoys Integration of Sensors / Weapons / Communication
Communication
NVD
Aero Engine SonarsAvionics Naval
Communication
Defence Public Sector Undertakings
Ordnance FactoriesProduct Profile
No. of Factories : 39 + 2 Principal Items - 881Manpower : 99000 (approx) Anti Tank Guns, Field Guns, Mortars, Small Arms, Bombs,
Rockets, Grenades, Mines, Depth Charge, Explosives, Propellants, Pyro Technique Stores, Transport Vehicles, Optical and Fire Control Instruments, Bridges,Assault Boats, Clothing / Protection Suits, Parachutes
Product ProfileNo. of Factories : 39 + 2 Principal Items - 881Manpower : 99000 (approx) Anti Tank Guns, Field Guns, Mortars, Small Arms, Bombs,
Rockets, Grenades, Mines, Depth Charge, Explosives, Propellants, Pyro Technique Stores, Transport Vehicles, Optical and Fire Control Instruments, Bridges,Assault Boats, Clothing / Protection Suits, Parachutes
Licensed Production Culture Poor Design innovation capabilityNo R&D Activity Outdated Production Management SystemNo Modernisation of production technologies Highly over staffedExcessive Government Control Poor Participation of private sectorOver Dependence on Licensor No initiatives for indigenization
BASANTPUSHPAK KRISHAK
PROGRESS OF INDIAN CIVIL AVIATION
HANSA
1960-70
1990’S AND BEYOND
SARAS
MIDDLE YEARS OF INDIAN MILITARY AVIATION1970-80
MIG-21
MIG-27
JAGUAR
LATER YEARS OF INDIAN MILITARY AVIATION1980-2000 AND BEYOND…..
CHEETAH CHETAK ALH
MIG-29 SU-30 LCA
OVERVIEW OF SYSTEMS & TECHNOLOGIES
DRDO52 Labs
Aeronautics Armament & Combat Engg
Missiles &Strategic Sys
Naval SystemsMaterials &
Life Sciences
Electronics
30,000 Workforce:• Scientists - 7000
• Technical Staff – 12,000
• Allied Staff – 11,000
OUR MISSIONOUR MISSION Design, develop and lead to production state-of-art defence systems and technologies Provide technological solutions to the Services to optimise combat effectiveness Develop infrastructure and committed quality manpower and build strong indigenous technology base
05/03/23
PRO
DU
CT
ION
ISA
TIO
N &
DE
LIV
ER
Y
EVOLUTION OF DEFENCE R&DEVOLUTION OF DEFENCE R&D
1958 1970 1980 1990 2000 2010
INC
EPT
ION
INSPECTIONAGENCY REVERSE ENGG.
TECHNOLOGY GENERATION
SCIENTIFICRESEARCH
MA
JOR
SY
STE
MS
& P
RO
GR
AM
ME
SIN
ITIA
TE
D
PRO
TO
TY
PES
& T
RIA
LS
IGMDPLCAMBT
EW SYSTEMS
IMPORT/EXPOSURE TO FOREIGN
TECHNOLOGIESDESIGN &
DEVELOPEMENT CONCURRENT
ENGG
LSP
, USE
R T
RIA
LS
& A
CC
EPT
AN
CE~ 20 YEARS
NE
W S
YST
EM
S
SYST
EM
ST
UD
IES
AN
D A
NA
LY
SIS
Funding
TYPICAL TIME FRAME FOR FIRST TIME SYSTEMS ELSEWHERE TOO
PROGRAMME DRIVEN PRODUCTION INFRASTRUCTURE
PROGRAMMES : SLV3, PSLV, IGMDP1970 – 1980 - 1990
IGMDP Management System• Three tier management system for Review and Execution• Concurrent development & production • Production agencies identified at conception of programme • Involvement of production agencies in development• Involvement of R&D labs in setting production infrastructure• DRDO/Space invested in HAL(ASD), BE, BEML, BDL, OF, ECIL• Strong Review Mechanism• Policy decision on - Cost plan development - Cost control - Redundancy management• Involvement of finance at every level
Benifits• Manufacturing technology upgradation at production agency
• Introduction of productionisation culture
• Improved quality assurance and certification system – MSQAA
• Ownership of programmes with synergy between R&D and PA
• Prithvi and PSLV production achieved in 5 years with involvement of - 40 Private Industries - 09 public Sector Industries
PROGRAMME DRIVEN PRODUCTION INFRASTRUCTURE (Contd)
INDUSTRIESHAL LARSEN & TOUBROBDL GODREJ & BOYCEBEL JOHNGALT INTLBEML SEC INDUSTRIESOF’S VEM ECIL RASU TOOLSKELTECH PRAGA TOOLS
REPUBLIC FORGE ECHJAY INDUSTRIES WALCHANDNAGAR
INDUSTRIESOF TRICHY LAXMI MACHINE TOOLS
TECHNOLOGIES / PRODUCTSAIRFRAME PROPELLANT TANKSWINGS NOSECONES ROCKET MOTORS LAUNCHERSRADARS PROPELLANTSWARHEADS DATA LINKS
• HMX, RDX, OCTOL EXPLOSIVES• LP ENGINE COMPONENTS• HYDRAULIC / PNEUMATIC ACTUATION SYSTEMS• INERTIAL SENSORS• INERTIAL NAVIGATION SYSTEMS• ON-BOARD COMPUTERSTECHNOLOGIES / PRODUCTS
FACILITIES
4/5 Axis Machining Centres Automatic Welding Equipment Magnesium Casting Facility Process Shop – Surface Treatments Vacuum Brazing Precision M/c Shop NDT Facilities for Propellants HIP, CIP, Spinning, Flow Forming Investment Casting; Powder Metallurgy products like Tungston
AEROSPACE MATERIAL PROCESSING Alluminium Alloys Magnesium Maraging Steel, 15 CDV6 Titanium Ni based super alloys Tungston Glass Fibre & Carbon Fibre
COMBAT AIRCRAFTS
AERONAUTICS
AEROSTAT UAV NISHANT
MICRO UAV TECHNOLOGIES
GRADUATION OF INDUSTRY
TECHNOLOGY TRANSFER
DESIGN & BUILD –
STRATEGIC PARTNER TO R&D
EVOLVE PROCESS &
MFG.
GR
OW
TH
• Process for Fab.• Eqpt. & Trg.• KOP
(L&T, BEL & OF)
L&T, Tata & BEML
DRDO INITIATED PROGRAMMES
1950-70 1980 1990 2000 2010
• Design by DRDO
• Build to Design
IGMDP, EW
T-72,BMP-II
MCP
MAL
• Build to Specification
INDUSTRY PARTNERSHIPINDUSTRY PARTNERSHIP
TataMTARGodrejL&TKCPCELASTRASEC ind. High Energy BatteriesAjay SensorsMACMETPEL
.
.
Tata L&T Deepti VEM Astra Ananth Tech Data Pattern ZetatechMACMETDynamatic TechnologiesDynalogAlpha DesgnApollo Micro SystemsRAP
.
.
.
...
Value addition
by industry
System Design specs
1970 1980 1990 2010
50
200
500
2000
100
Fabricator
Fabrication & Testing
Subsystem, Design, Fabrication & Testing
LRSAMDRDO+ Israel+ Indian
Industries
BrahmosDRDO+ Russia+ Godrej
SRSAMDRDO+ MBDA
Aero EngineGTRE + CIAM
GTRE + SNECMA
I2MCUncooled
FPA, MEMS
.
.
GlobalCollaboration
2020
FUTURE SYSTEMS & OPPORTUNITIES
Indian Aerospace Industry – an attractive opportunity
India’s presence in all segments of Aerospace Value Chain
Major global aerospace companies present in India in some way or the other
• India – one of the fastest-growing aerospace markets in the world• Mostly due to defence spending and growing commercial aviation market• Expected to add ~ 4000 military and commercial aircrafts in next 15 yrs • MRO segment estimated to grow at 10% and reach USD 2.6 bn by 2020
This would require significant investment in capacity building
17
India is expected to be the third largest Aerospace market after U.S. and China by 2020
Development Programs:•Aeronautics, Armaments, Combat vehicles• Electronics, Missiles, Materials•Medium Multi Role Combat Aircraft (MMRCA) •Fifth Generation Fighter Aircraft (FGFA) •Multirole Transport Aircraft (MTA) •Medium Lift Helicopters (MLH) •Light Utility Helicopters (LUH)• Hypersonic vehicles
Development Programs:•Satellite Launch Vehicles•PSLV , GSLV •Satellites•INSAT , IRS
Intensive technology and safety requirements mandate significant investments in R&D and quality control
• India projected as 5th largest buyer of passenger aircrafts
• Commercial aircraft projected to grow at 6% CAGR
• Business jets to grow at 11% CAGR
• Modernization underway:• Airports• Communications • Radars
• Facilities for MRO
• 10th biggest spender in defense. FY 13 budget – USD 35bn
• Expected to spend USD 100 bn in next decade
• Military expected to add 1000 rotary & 1200 fixed wing aircrafts
18
WEAPON SYSTEM DEVELOPMENT – NEXT 30 YEARS WEAPON SYSTEM DEVELOPMENT – NEXT 30 YEARS Missiles
• Hypersonic and sub-sonic cruise missiles
• Long range ballistic missiles with MIRV
( multi-platform – land, air, under-water)
• Ballistic & cruise missile defence
systems with space segment
• Multi-platform tactical missiles &
missile based PGM’s
Naval Systems
• Torpedoes with thermal engines
Aeronautics
• UAV, UCAU, aerostats, airships with
multiuse payloads
• Multi role stealth combat aircraft
EW Systems
• Multi-platform EW systems
• Cyber warfare systems
Armaments & Combat Systems
• Next generation MBT, APC
• Remotely piloted reconnaissance ground
vehicles
• Low cost guided multi-barrel rockets with
PGM’s
• Self propelled guns with PGM’s.
New Concept Weapons
• Directed Energy
- Lasers, micro-wave, particle beams
• Kinetic Energy
- EM cannons, kinetic kill vehicle
• Non-Anti Personnel
- Chemical energy-losing agents,
Low energy-laser blinding weapons,
Omni directional irradiation weapons
19
TECHNOLOGIESMISSILES•MEMS based actuators, sensors• RF seekers – Electronically steered arrays, Power source, klystrons, MPM, signal processing, ATR• Gel propulsion systems• Navigation sensors - RLG, FOG, DTG, HPM, Navigation on chipELECTRONICS • IIR Seekers – focal plane arrays, bolometers, CCD’s, adaptive optics, IR domes• Laser seekers• Network centric warfare technologies• Active phased array radars• Space based IR sensors, SAR• Secured multi-layer high speed communication network• Mini & micro Satellites• VLF, ELF, blue-green laser • SDRMATERIALS• Ceramic radomes• High temperature materials• Stealth materials
AERONAUTICS • Airborne (AEWS, ESM, ECCM Systems)• Gas turbine engines• Stealth technologies • Robotics & unmanned vehicles
ARMAMENT & COMBAT TECHNOLOGIES• High energy solid propellants (ADN) • Pulse detonation engines• Thermobaric warheads• Automated, composite, bridging systems• Soldier as a system• Low intensity conflict technologies
LIFE SCIENCES• NBC defence Technologies
NANO TECHNOLOGIES• NANO materials, nano sensors, • NANO structures, nano electronics
WARGAMING• Wargaming, modelling & simulation of defence systems
TECHNOLOGY DEVELOPMENT – NEXT 30 YEARS TECHNOLOGY DEVELOPMENT – NEXT 30 YEARS
20
EMERGING DEFENCE & AEROSPACE MARKET (2010-2025)
• IMPORT PRODUCTS (BUY-Make) approximate estimates– MMRCA Rs.42,000 Cr
– Guns Rs.8000 Cr
– C-17 Aircrafts Rs.25,000 Cr
– MIRAGE Upgrade Rs.10,000 Cr
– Helicopters Rs.10,000 Cr
– Missiles Rs.7,000 Cr
• INDIGENEOUS PRODUCTS (Make India)– Missiles Rs.1,03,600 Cr
– Aircrafts• Light Combat Aircraft Rs.57,000 Cr• FGFA Rs.30,000 Cr• AEW&C Rs.2000 Cr• AWACS Rs.6000 Cr• UAV’s Rs.2000 Cr
EMERGING DEFENCE & AEROSPACE MARKET (2010-2025) contd
• INDIGENEOUS PRODUCTS (Make India)• Rockets Rs.1100 Cr
• Tanks Rs.3000 Cr
• EW Systems Rs.1500 Cr
• Radars Rs.7000 Cr
• Naval Systems Rs.1200 Cr
• Field Gun Rs.2000 Cr
• Electro Optical Systems Rs.1000 Cr
• Helicopters• ALH Rs.8000 Cr• LCH Rs.5000 Cr
05/03/23 DRDO - An Overview 23
GLOBAL TECHNOLOGY GROWTH
AEROSPACE & DEFENCE MANUFACTURINGCHARACTERIZED BY
• COMPLEX DESIGNS AND LONG PROJECT CYCLE
• LARGE R&D INVESTMENTS
• LARGE INVESTMENTS IN MANUFACTURING & TEST EQUIPMENT
• MATERIALS OF UNIQUE SPECIFICATIONS
• ADVANCED MANUFACTURING TECHNIQUES
• PHYSICAL SIZES RANGING FROM MMS TO FEW METERS.
• LOW BATCH SIZES – OFTEN ONE OFF.
• FAST TECHNOLOGICAL OBSOLESCENCE
• DIVERSE TECHNOLOGIES
• INTENSIVE TECHNICAL, QUALITY AND SAFETY REQUIREMENTS
• STRINGENT REGULATORY ENIVRONMENT
• SUPPLY CHAIN MANAGEMENT
FRAMEWORK OF ADVANCED MANUFACTURING TECHNOLOGY
Source: IDA Report 2012, Emerging Global Trends in Advanced Manufacturing
FRAME WORK OF ADVANCED MANUFACTURING TECHNOLOGY
ADVANCED PRODUCTS
• Technologically Complex• Use New Materials• Highly Sophisticated designs• Innovative products
SMART MANUFACTURING ENTERPRISE CONCEPTS
• Manufacturing goes beyond the factory floor• Paradigms of “Manufacturing as Eco- System” have emerged• Smart Enterprises create and use data and information throughout he product life cycle• Create Flexible Manufacturing processes to cater for changes in demand at low cost without damage to environment• Product design to facilitate efficient production and re-cyclability
ADVANCED PROCESSES & TECHNOLOGIES
• Advanced Manufacturing consisting of ‘Know How’ of production with focus on Advanced Processes & Technologies
BUILDING BLOCKS (DRIVERS)
• Breakthroughs in Physics, Chemistry, Material Science & Biology• Convergence of Physics, Chemistry, Material Science & Biology• Advances in computational modelling & prediction along with computational power
Water Jet Machining Hexapod Machining Multi Tasking Machines Role Extrusion for Missile cases Single Crystal based Super Alloys for Gas Turbines Engines (BLISK) Integral Fuselage Design & Manufacture (Welded structures) – Extrusions, Laser Beam Welding, Friction Stir Welding Near Net Shape Manufacturing Advanced Aluminum Alloys & Fabrication technologies for Space Transportation Systems – Near Net Extrusion
ADVANCED AEROSPACE & DEFENCE MANUFACTURING TECHNOLOGIES 2005 & BEYOND
Roll Forging Cryogenic Tanks Shear Forging Adaptor Rings Spin Forming for Tank Domes Friction Stir Welding Internally Stiffened Extrusions High Voltage electron Beam Welding
- Reactive Material Ti-6Al-4V Alloy- Multiple Tier Welding, Multi-thickness welding
Friction Stir Welding Laser Consolidation Processing Laser Engineered Net shaping Vacuum Plasma Sprays Photo Chemical Machining
ADVANCED AEROSPACE & DEFENCE MANUFACTURING TECHNOLOGIES 2005 & BEYOND (CONTD)
MESO / Micro Mechanical Manufacturing (M4) Micro EDM Focused Ion Beam Machining (FIB) Feinto – Second Lasers Micro USM Micro Turning
Thermal Barrier Coating Processes Near Net Shape manufacturing of Advanced Ceramics – Gel Cast Ceramic Radome Surface Micro Machining & Bulk Micro Machining processes for Sensors, Actuators Nano Technology
ADVANCED AEROSPACE & DEFENCE MANUFACTURING TECHNOLOGIES 2005 & BEYOND (CONTD)
Metallic Materials Aerospace Grade Shape ApplicationAluminum Alloys
2xxx (Al-Cu-Mg)7xxx (Al-Zn-Mg-Cu-Zr)6xxx (Al-Mg-Si)
SheetPlateExtrusionForgings
Aircrafts, Missiles, Launch Vehicles, UAVs, Bridges
Lithium – Aluminum Alloys
- do - Aircraft Structures
Titanium Alloys Ti-6Al-4vTi-10V-2Fe-Al
- do - Aircrafts, Missiles, Tanks, Rockets, Armaments, Engg Eqpt
High TemperatureMaterials
Titanium AlloysNimonic AlloysNiobium Alloys
- do -Metallic Honey Comb & Foams
Missiles, Aero-Engines, Launch Vehicles, Scramjet, Hypersonic Aircrafts and Missiles
Metal-Metal composites based on Nb, Ti, Polymer and SiC
C-CC-SiCSiC-SiCTaC / Ta2CMo-Si-BNB-Si-CMo-Si-BTi-AlPt-Al
Investment opportunities in Aerospace & Defence MaterialsCharacteristics : High Quality – Low Volume – Technology Denied
Metallic Materials Aerospace Grade Shape ApplicationSuper Alloys
Nickel basedTitanium based
Thermal Protection Coatings
ZirconYiltrium stblised ZrSi3N4
Special Steels 11-10 PH SteelMaraging Steel 350/250Ultra High Strength Steels (AB2/AB3)
Ship, Submarine, Rocket Engines, Aero Engines, Engg.Structures, Armaments
Investment opportunities in Aerospace & Defence Materials - contd
Metallic Materials Shape ApplicationSiliconGallium ArsenideGermaniumCadmium Zinc TellurideMercury Cadmium TellurideGallium NitrideSi Carbide
Bulk CrystalsWafersEpitaxial Layers (nm - µm
Sensors, Lasers / Detectors, VLSI, MEMS, MMIC, Optical Components
Functional Materials
Characteristics : Ultra High Purity R/M 7 N to 9N
EMERGING SCENARIO IN INDIAAND
TRANSFORMATION STRATEGY FOR MEETING THE CHALLENGES
Emerging Eco System 2000 +Emerging Eco System 2000 +
Emerging Eco System 2000 +Emerging Eco System 2000 +
New Collaboration Models
TYPE SYSTEM PARTNERSJOINT DEVELOPMENT - LR SAM – LONG RANGE
SURFAVCE TO AIR MISSILE- INDIA (DRDO)- ISRAEL (IMI)
JOINT VENTURE - BRAHMOS - INDIA (DRDO)- RUSSIA
EXCHANGE OF SCIENTISTS - BMD PROGRAMME - INDIA - BELARUS
COLLABORATIVE RESEARCH - GYRO & NAVIGATION SENSORS DEVELOPMENT- PGM DEVELOPMENT
- INDIAN UNIVERSITIES / RESEARCH INSTITUTIONS - GLOBAL PARTNERS
Royalty Model (Outright sale off of mature technologies )
Total Risk-Revenue Partnership Sharing Model ( Partnership from the stage of Conceptualization)
Partial Risk-Revenue Sharing Partnership Model ( Partnership from certain level of Maturity)
Models for Public Private Partnership
Micro financing in Indian Defence Sector • Promoting Micro financing in Indian Defence Sector, specifically, in
Sensitive & Strategic areas is essential to achieve sustainability in defence supplies to services.
• Initially, High cost investment vs Low volume turn over in defence sector.
• Raising FDI limit with certain overriding protection clauses to safeguard Industry / Self Reliance Interest.
• Indian Private industry must be promoted & supported by micro financing to ensure Indian defence sector commercially competitive.
• Modes of Micro Financing to Private Industry.– Micro financing by Govt. – Micro financing by Private institutions – Availability of subsidized loans. – Operation of facilities on GOCO basis
Creation of a National Aerospace and Defence Technology Commission to Coordinate, Review, Prioritize and take decisions on investment, collaborations, Export and joint ventures & give direction to aerospace & defence production for improving countries self reliance, GDP and finding the right place as developed nation in the aerospace sector against global competition.
Strategy for Accelerated Technology Strategy for Accelerated Technology UpgradationUpgradation
Strategies for Improved Industry Participation in
Defence & Aerospace Sectors
Collaboration and Synergy with indigenous R&D System to strengthen “Know-How” and “Know-Why” aspects of technology development and production. It will provide
High Performance Cost Effectiveness Availability on Demand Product Life-Cycle Support Software Upgradation Concurrency of Development and Productionisation
and augmentation of production infrastructure and Technology Transfer and Absorption Shorter time from Concept to Delivery to market
Aerospace & Defence Industry Complex
Aerospace Industrial Complex- Comprehensive solution for Space & Defence Sectors
• Proposed Aeroparks can become Industrial Complexes• Existing skills of Auto Industry will complement the Aviation in utilizing the highly skilled & qualified manpower• UAVs, Civil Aircraft – Production and Maintenance opportunities• Existing IT skills can be utilised for CAD/CAM• Deposits of titanium Ore – highly used in aerospace industry• World Class research facilities to be tapped for industrial application