L&T’s Robotic Drilling Machine Revolutionizes LCA Tejas Wing Production, Slashing Drilling Time by 95%

India’s push for self-reliance in defence manufacturing has taken a significant leap forward with Larsen & Toubro’s (L&T) introduction of a robotic drilling machine for the Light Combat Aircraft (LCA) Tejas. This cutting-edge automation has transformed the production of Tejas fighter jet wings, reducing the drilling time per hole from 25-35 minutes to just one minute—an improvement of over 95%.

Hindustan Aeronautics Limited (HAL), the manufacturer of the Tejas, has been striving to accelerate production to meet the Indian Air Force’s (IAF) growing demand, particularly for the advanced LCA-Tejas Mk1A variant. One of the major bottlenecks in the process was the manual drilling of around 8,000 holes required for each wing set, a task that previously consumed thousands of hours.

Recognizing the need for efficiency, L&T, a key supplier of Tejas wings, introduced an advanced robotic drilling system to automate the process. The new system can drill approximately 66% of the required holes—about 5,280 out of 8,000—significantly reducing production time.

What makes this system revolutionary is its ability to maintain precision and consistency. Equipped with sophisticated sensors and automated control mechanisms, the robotic machine dynamically adjusts for variations in material thickness and type, ensuring high accuracy while minimizing errors, rework, and material wastage.

The impact of this automation is staggering. Under the manual process, drilling 5,280 holes would take an estimated 2,640 hours. The robotic system now completes the same task in just 88 hours, saving over 2,500 hours per set of wings. This drastic reduction in production time allows HAL to scale up Tejas deliveries, bringing India closer to its goal of delivering 16 to 18 aircraft annually.

By integrating such cutting-edge automation, India is not only advancing its indigenous fighter jet program but also laying the foundation for more efficient aerospace manufacturing in the future. This breakthrough is a testament to the country’s growing technological capabilities and its commitment to self-sufficiency in defence production.