High-Density Automated Intralogistics Solution for Regional Aircraft Manufacturing

Deutsche Aircraft and Jungheinrich have partnered to deploy an integrated automated intralogistics solution at a digital final assembly line in Leipzig/Halle, Germany. This deployment combines a compact bin storage system and a very narrow aisle warehouse to streamline material supply and optimize physical space for high-volume aerospace manufacturing.

Operational Challenges in Aerospace Manufacturing
Deutsche Aircraft developed a fully digital, paperless assembly line for its D328eco regional aircraft program. To support this facility, the manufacturer required a highly space-efficient material supply infrastructure capable of managing thousands of small components and larger pallets. The primary operational goal was to establish a logistics system that could minimize physical footprint while remaining scalable to support a planned production ramp-up of 48 aircraft per year.

Integrated System Architecture
To address these capacity and space requirements, Jungheinrich deployed a dual-system automated intralogistics solution operating under a single Warehouse Control System. The architecture combines a compact bin storage system for small parts with an automated very narrow aisle warehouse (AutoVNA) for large components.

The compact bin storage system consolidates over 6,500 containers across 26 levels within a 210-square-meter footprint. Sixteen shuttles transport bins between storage locations and five workstations. The control system optimizes retrieval times by automatically storing high-throughput components on lower levels, while less frequently accessed parts are shifted to upper levels. To mitigate fire hazards, the entire bin storage area operates in a reduced-oxygen environment.

For larger materials, the AutoVNA manages 624 pallets across two aisles utilizing two autonomous storage and retrieval trucks. A conveyor system connects the receiving area, six picking stations, and the shipping zone. During transit, every pallet undergoes an automated barcode scan to verify dimensional conformity and weight. Additionally, the facility utilizes 135 cantilever storage positions to handle long goods required for aircraft assembly.

Scalability and Footprint Reduction
The integrated architecture minimizes the physical footprint of the logistics center while keeping necessary assembly components in close proximity to the production line.

Sebastian Böhnl, Vice President Operations & Production at Deutsche Aircraft, noted that the D328eco program required a logistics infrastructure capable of scaling alongside production. He stated that the combined system ensures component availability for assembly while operating within a significantly smaller footprint than alternative solutions evaluated.

Dr. Tobias Harzer, Member of the Board for Automation at Jungheinrich, explained that the configuration maximizes storage density for small parts while the narrow aisle warehouse keeps larger components available close to production, creating a unified material supply solution.

The Leipzig/Halle logistics facility is designed for two-shift operations and contains the structural capacity to expand to three shifts as manufacturing volumes increase.

Edited by Aishwarya Mambet, Induportals Editor, with AI assistance.

www.jungheinrich.com