Jungheinrich has officially handed over the automated logistics center at Leipzig/Halle, Germany, Airport to Deutsche Aircraft. The logistics center is a key component of Deutsche Aircraft’s industrialization strategy for the D328eco program, providing the automated material supply required to support future production ramp-up. In a pioneering implementation, the Jungheinrich PowerCube automated compact bin storage system and an automated very narrow aisle warehouse (AutoVNA) operate together under a single control system.
With its “Factory 4.0” at Leipzig/Halle Airport, Deutsche Aircraft has developed a fully digital, paperless final assembly line for regional aircraft, equipped with an integrated automated intralogistics solution. The system provides highly space-efficient storage for thousands of small parts and pallets and is fully integrated into the digital process chain.
Sebastian Böhnl, Vice President Operations & Production at Deutsche Aircraft, said: “As we prepare to ramp up production towards a capacity of up to 48 aircraft per year, the D328eco program requires a logistics infrastructure that can scale alongside it. The Jungheinrich PowerCube and AutoVNA provide exactly that, ensuring every part is available when it is needed for assembly, all within a significantly smaller footprint than any other solution we evaluated. At the same time, the system provides substantial capacity for future growth.”
Two material flows, one control system
Within the Jungheinrich PowerCube, 16 shuttles move bins between storage locations and five ergonomic workstations. Frequently used components are automatically stored on the lower levels because of their higher throughput, while less frequently accessed parts gradually move to upper levels over time. Components required for assembly are staged in dedicated preparation shafts, enabling rapid access to pre-configured assemblies. The storage area operates in a reduced-oxygen environment to minimize fire risk.
In the very narrow aisle warehouse, two EKX 516ka trucks autonomously store and retrieve Euro pallets. Conveyor technology connects the receiving area, six picking stations, and the shipping area. During transport, every pallet is scanned via barcode and automatically checked for dimensional conformity and weight. For long goods, Jungheinrich also supplied 135 cantilever storage positions serviced by electric forklifts.
All transport movements in both systems are coordinated by a shared Jungheinrich Warehouse Control System.
Dr. Tobias Harzer, Member of the Board for Automation at Jungheinrich, explained the benefits of the combined solution: “The PowerCube maximizes storage density for small parts in the smallest possible space, while the very narrow aisle warehouse keeps pallets with larger components readily available close to production. Each system leverages its respective strengths, and together under a unified control system they create a material supply solution that minimizes space requirements while supporting future production increases. Deutsche Aircraft is the first customer to implement this combination, and certainly will not be the last.”
Ready for production ramp-up
The facility has been designed for two-shift operation and can be expanded to three shifts to support future production ramp-up. At full capacity, between 250 and 350 employees will manufacture up to 48 aircrafts per year at the Leipzig/Halle site, establishing Leipzig/Halle as the industrial center of excellence for the D328eco program.
The advanced logistics infrastructure forms a key part of Deutsche Aircraft's industrialization strategy for the D328eco program, enabling efficient material flow and scalable production as manufacturing volumes increase.
