Jungheinrich & Deutsche Aircraft set a new standard in aerospace logistics with automated warehouse for next-generation regional aircraft production

In a landmark step towards next-generation regional aircraft manufacturing, Jungheinrich has delivered an advanced automated logistics centre to Deutsche Aircraft at Leipzig/Halle Airport. Supporting the production readiness of the D328eco programme, the facility combines the innovative Jungheinrich PowerCube automated compact bin storage system with an automated very narrow aisle warehouse under one unified control system, creating a highly efficient and scalable logistics environment for future aircraft assembly operations.

As part of its innovative Factory 4.0 initiative at Leipzig/Halle Airport, Deutsche Aircraft has established a fully digital, paperless final assembly line for regional aircraft, seamlessly integrating advanced automated intralogistics into the production process. Designed to maximize efficiency and support future manufacturing growth, the solution delivers high-density storage for thousands of components and pallets while remaining fully connected to the aircraft manufacturer's end-to-end digital production ecosystem.

To enable this next-generation logistics capability, Jungheinrich integrated its PowerCube automated compact bin storage system with an automated very narrow aisle warehouse (AutoVNA) under a single intelligent control platform. Despite occupying just 210 square metres, the PowerCube provides capacity for more than 6,500 containers across 26 storage levels, while the AutoVNA system efficiently manages 624 pallet locations across two aisles, creating a highly space-efficient and scalable logistics environment.

Sebastian Böhnl, Vice President Operations & Production at Deutsche Aircraft, commented: "As we prepare to ramp up production towards a capacity of up to 48 aircraft per year, the D328eco programme 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 intelligent control platform

At the heart of the facility, the Jungheinrich PowerCube delivers highly efficient automated small-parts storage, with 16 shuttles transporting bins between storage locations and five ergonomic workstations. Frequently required components are dynamically positioned on lower levels to accelerate retrieval, while slower-moving inventory is automatically relocated to upper levels. Dedicated preparation shafts allow assembly kits to be staged in advance, ensuring rapid access to pre-configured components. To further enhance operational safety, the entire storage system operates within a reduced-oxygen environment designed to minimise fire risk.

Complementing the PowerCube, the automated very narrow aisle warehouse is equipped with two autonomous EKX 516ka trucks responsible for the storage and retrieval of Euro pallets. An integrated conveyor network links goods receiving, six picking stations and outbound shipping operations, creating a seamless material flow. Every pallet is automatically scanned and verified for barcode accuracy, dimensional compliance and weight during transit. For oversized and long components, Jungheinrich additionally installed 135 cantilever storage positions served by electric forklift trucks.

Bringing both environments together, all storage, retrieval and transport activities are orchestrated through a single Jungheinrich Warehouse Control System, providing full transparency, synchronised material flows and maximum operational efficiency across the entire logistics centre.

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."

Built for scalable aircraft production

Designed to support the next phase of the D328eco programme, the Leipzig/Halle facility is configured for two-shift operations and can be expanded to a three-shift schedule as production volumes grow. At full capacity, the site is expected to employ between 250 and 350 specialists and deliver up to 48 aircraft annually, reinforcing Leipzig/Halle’s position as Deutsche Aircraft’s industrial centre of excellence for the next-generation regional turboprop.

The advanced logistics infrastructure plays a central role in Deutsche Aircraft’s industrialisation roadmap, ensuring a reliable, automated flow of materials across the production environment. By combining scalability, efficiency and digital integration, the facility provides the operational foundation required to support increasing manufacturing rates and long-term programme growth.