The Airbus H160: redefining mission readiness and support

A flagship of helicopter innovation, the Airbus H160 also represents a fundamental shift in how rotorcraft are maintained and supported. Since its entry into service, the H160 has consistently demonstrated an availability rate of approximately 90%. This level of reliability is the result of a meticulously planned ecosystem where design simplicity, digital maturity, and human expertise converge to keep missions on track. 

Designed with the technician in mind

High availability begins on the drawing board. From the very first blueprint, the H160 was engineered to minimise maintenance workload and increase fleet availability. Throughout the conception phase, design engineers worked alongside operator technicians and maintenance engineers to ensure that looking after the aircraft would be as easy as possible for operators in the field.

The strategy was threefold: reduce the number of moving parts, make access to those parts easier, and make the interval between maintenance checks as long as possible. This focus was not limited to the hardware itself, but encompassed the entire working environment for technicians. For example, the H160’s design includes built-in steps so technicians can climb up easily. Once there, cowlings slide to the side, allowing them to stand upright rather than crouching, as well as easily access the part and complete the task efficiently. 

Babcock, which maintains the intermediary H160 fleet for the French Navy’s search and rescue missions, recently shared feedback after the first 900-flight-hour visit. Jonathan Murgier, Head of H160 maintenance check at Babcock France, said: “This first visit for maintenance was very straightforward for our teams. The floor is much more spacious, making for easier access to the parts we needed to examine. We encountered no difficulties.”

Several operators have now completed this 900-flight-hour milestone which firmly validates the programme’s original vision: minimising the aircraft’s downtime to allow for continuity of operations. This sentiment is echoed across the industry. Merck Aviation, one of the first private and business operators of the H160, has already seen its maintenance time per flight hour decrease by about 30%, compared to its previous fleet. 

Operator Zero: maturity from day one

A cornerstone of the H160’s successful entry into service is the “Operator Zero” campaign. This is the name given to the team that simulates real-world operator maintenance tasks on the H160, encountering and resolving any maturity issues long before a customer ever sees them. By performing all maintenance tasks exactly as an operator would, the team ensures the process is clear and streamlined. 

This innovative approach represents a revolution in how new helicopters enter service. By stepping into the customers' shoes, the Operator Zero teams merge technical expertise with a real-world perspective to create pragmatic maintenance kits. These kits guide operators through every detail: from selecting the right tools and sequencing tasks to efficiently organising maintenance slots. 

The digital edge: a paperless revolution

The H160 is a pioneer of the ‘digital hangar’ and has gone entirely paperless. This transition means technicians can intervene more efficiently with significantly reduced downtime. Through the integration of digital tools, maintenance has evolved to become simpler and more accurate, greatly reducing the possibility of human error.

A key example of this is the Wireless Airborne Communication System, or “WACS”. This system automatically transfers all crucial metrics, such as the number of landings, cycle variations, and component aging, to support teams on the ground at the end of each flight. With WACS built into the avionics, the data is precise, immediate, and shared seamlessly with Airbus experts.

A human-centric support network

While new technology is a key driver for efficiency, a robust support network remains essential. Airbus has a dedicated team of Technical Representatives (Tech Reps) along with customer support and logistic managers who act as the point of contact for operators globally. For this team, the customer is at the centre of everything they do, fostering a culture that is both reactive and proactive.

There is also a genuine ‘H160 community’, built on close collaboration between customers and Airbus. Every year, Airbus hosts H160 operators at its headquarters in Marignane to discuss challenges and work together toward the shared goal of keeping aircraft flying safely and efficiently.

A prime example of this commitment was the Route Proving programme with PHI in the United States. By collaborating closely in a real-world energy sector environment, support teams fine-tuned the helicopter's capabilities and support structure before full-scale deployment. Whether it is the French Navy performing life-saving missions or corporate operators like Merck, the benefit of this proximity is clear. As Michael Wallis, Associate Vice President at Merck Aviation Services, noted: "The H160 is truly well supported by Airbus”.