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Integrated Base Overhaul & Modernization

Comprehensive facility upgrade, fleet retrofit, and digital systems integration program designed to extend operational lifecycle, improve MTBF, and align with next-generation aerospace standards.

Primary Bays Online
NDT Certification Active
Avionics Bench Upgrade (72%)
Safety Compliance: 100%

Program Scope & Objectives

The Base Overhaul Initiative addresses infrastructure aging, tooling obsolescence, and digital fragmentation across all AeroVance depot facilities.

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Assets In Queue
↑ 12% capacity vs Q3
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First-Pass Yield %
↑ 2.1% improvement
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Day Avg Turnaround
→ Target: 21 days
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Safety Incidents
✓ 412 days LTI-free

Hangar Expansion

24,000 sq ft climate-controlled assembly bay with HEPA filtration, vibration isolation flooring, and modular power distribution for high-draw test equipment.

Clean Room Integration

ISO Class 7 rated environment for avionics sensitive component handling, ESD-safe workbenches, and controlled humidity management.

Tooling & CNC Fleet

Deployment of 5-axis CNC machining centers, automated metrology arms, and laser scanning for rapid reverse engineering of legacy parts.

Utility & Power

Redundant 480V/3-phase distribution, uninterruptible power systems (UPS) for critical test benches, and nitrogen/oxygen piping networks.

Structural Life Extension

Comprehensive airframe inspection, crack repair protocols, composite patching, and stress relief treatments per OEM SBs and ADs.

Propulsion Overhaul

Hot section inspection, turbine blade reprofiling, fuel system calibration, and performance restoration to within 0.5% of BHP ratings.

Landing Gear & Brakes

Bogey reassembly, shock strut overhaul, brake assembly replacement, and rigging verification per manufacturer torque specs.

Cabin & Systems

Interior refurbishment, HVAC sanitization, electrical harness retermination, and oxygen system certification.

Digital Twin Integration

Real-time asset tracking, predictive maintenance modeling, and lifecycle simulation for every component entering the overhaul pipeline.

Avionics Programming

Loadable software updates, FPGA configuration, GPS/INS alignment, and cockpit display certification per DO-178C standards.

NDT Automation

Phased array ultrasonic testing (PAUT), eddy current array (ECA), and thermographic inspection with AI-assisted defect classification.

Data & Traceability

Blockchain-secured component history, RFID tracking, and automated generation of FAA/CAAC/EASA airworthiness release forms.

Overhaul Process Timeline

Standardized 5-phase workflow ensuring quality control, regulatory compliance, and predictable throughput.

Phase 01

Receiving & Initial Inspection

Documentation verification, visual assessment, tag-out procedures, and baseline weight/balance recording.

Phase 02

Disassembly & NDT

Systematic breakdown to line-replaceable units (LRUs), non-destructive evaluation, and corrosion assessment.

Phase 03

Repair, Refurb & Upgrade

Machining, composite repair, electrical rework, software flashing, and integration of service bulletin modifications.

Phase 04

Integration & Functional Test

Reassembly, pressure testing, vibration screening, avionics bench check, and ground run simulation.

Phase 05

Quality Assurance & Release

Final inspection, airworthiness certification, documentation package generation, and shipping preparation.

Compliance & Quality Standards

All overhaul activities are executed under strict regulatory oversight and internal quality management systems.

AS9
AS9100D Rev D
Aerospace Quality Management
ISO
ISO 9001:2015
General Quality Systems
FAA
FAA Part 145
Repair Station Certification
MIL
MIL-STD-810H
Environmental Engineering
DO-
DO-178C / DO-254
Software & Hardware Airworthiness
ITAR
ITAR Compliant
Defense Export Control

Technical Request Portal

Submit overhaul requirements, request capability briefings, or schedule facility assessments.