Deutsche Aircraft pairs PowerCube and AutoVNA for D328eco

A combined PowerCube and automated very narrow aisle warehouse has been installed at Leipzig/Halle to supply the D328eco final assembly line as production ramps up.

Deutsche Aircraft's "Factory 4.0" at Leipzig/Halle Airport has been equipped with an integrated automated intralogistics solution from Jungheinrich, serving its fully digital, paperless final assembly line for the D328eco regional aircraft. The system provides highly space-efficient storage for thousands of small parts and pallets and is fully integrated into the digital process chain.

Jungheinrich has combined the PowerCube automated compact bin storage system and an automated very narrow aisle warehouse (AutoVNA) under one integrated control system. On a footprint of approximately 210 square metres, the PowerCube accommodates more than 6,500 containers across 26 levels, while the AutoVNA handles 624 pallets in two aisles. Deutsche Aircraft is the first customer to implement the combination.

Within the 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 minimise 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, with every pallet scanned via barcode and automatically checked for dimensional conformity and weight during transport. 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.

“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,” says Sebastian Böhnl, vice president operations and production at Deutsche Aircraft.

“The PowerCube maximises 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,” says Dr Tobias Harzer, member of the board for automation at Jungheinrich.

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 aircraft per year at Leipzig/Halle, the industrial centre of excellence for the D328eco programme.