Jabiru Aircraft last week launched Operation Bulletproof, an initiative to transform its Gen4 engines into the "gold standard" in lightweight aircraft engines.
Aiming for an increase in reliability and durability, Jabiru has admitted at times their engines have fallen short of industry expectations for both.
"While Jabiru aircraft have earned their reputation for exceptional ruggedness and durability, we recognize our engines have not consistently met the same exceptional benchmark," the company said when announcing Operation Bulletproof.
"Our GEN4 engines deliver world-leading power-to-weight-to-cost ratios through our approach of refined simplicity, but we're setting our sights higher–we're not content with meeting industry standards; we aim to redefine them."
Jabiru has detailed six key initiatives central to the success of Operation Bulletproof:
- enhanced knowledge-sharing – more robust systems for distributing technical information and best practices
- revitalised service documentation – redesigned service notices and manuals with increased frequency and clarity
- Jabiru approved maintainers – providing access to local expertise in maintenance of Jabiru products
- owner/maintainer education – relaunching maintenance training courses for owners
- supply chain excellence – rigorous review and enhancement of vendor quality standards
- refined quality processes – continuously refining our quality systems throughout manufacturing.
Jabiru Executive Director Mick Halloran emphasised the need for the engines to match the airframe in terms of reliability.
"Today's pilots expect push-button reliability," he said. "Operation Bulletproof represents our commitment to delivering
engines that perform flight after flight, with the same unwavering dependability as Jabiru aircraft."
In November 2014, CASA imposed operational restrictions on aircraft fitted with Jabiru engines after what it said was a "high, and increasing, rate of engine failures among aircraft that are powered by engines manufactured by, or under licence from, Jabiru Aircraft Pty Ltd."
In 2016, an ATSB investigation report stated that of 322 engine failures in aircraft with MTOWs below 800 kg, 40% involved Jabiru engines, and of those engines, 47% could be attributed to 3/8" through-bolts fracturing.
Jabiru subsequently increased the diameter of the through-bolts to 7/16". CASA subsequently removed the operational restrictions for aircraft running engines with the new diameter bolts.
Jabiru has been manufacturing engine since the 1600 motor in 1992, introducing the four-cylinder 2200 engine in 1998 and the six-cylinder 3300 shortly after. It also turned out a small number of eight-cylinder 5100 engines.