Translation note: This article was translated with the assistance of AI.
Jungheinrich has handed over the new automated logistics center at Deutsche Aircraft’s Leipzig/Halle Airport site. For the first time, the company’s PowerCube compact tote storage system and an automated very narrow aisle warehouse are operating under a shared control system. The facility will supply the future D328eco production line.
Deutsche Aircraft has commissioned a largely automated intralogistics system for its future D328eco production at Leipzig/Halle Airport. Jungheinrich officially handed over the logistics center in early October. It forms part of Deutsche Aircraft’s new Factory 4.0 and will supply material to final assembly.
Technically, Jungheinrich is combining two of its automated storage systems in a single application for the first time. The PowerCube primarily handles smaller parts in totes, while an automated very narrow aisle warehouse, referred to by Jungheinrich as AutoVNA, stores pallets carrying larger components. All transport movements are coordinated by a shared Warehouse Control System.
More than 6,500 totes on 210 square meters
The PowerCube makes extensive use of the available building height. More than 6,500 tote storage locations are arranged across 26 levels within a footprint of around 210 square meters. Sixteen shuttles move the totes between storage positions and five ergonomic workstations.
The storage strategy adjusts to actual demand. Frequently used parts are automatically kept on lower levels, where the shuttles can access them more quickly. Less frequently requested items are gradually moved to higher levels.
Separate preparation shafts are available for preconfigured assemblies. Components required for production can therefore be staged in advance. The storage area itself operates with a reduced oxygen concentration as a preventive fire protection measure.
Autonomous VNA trucks handle 624 pallets
Larger components are stored in an automated very narrow aisle warehouse with 624 Euro-pallet locations. Two autonomous Jungheinrich EKX 516ka VNA trucks handle storage and retrieval in two aisles.
A conveyor system links goods receiving, six picking stations and the shipping area. Each pallet is identified by barcode during transport. At the same time, the system automatically checks its dimensions and weight. This allows deviations to be detected before the pallet enters the downstream material flow.
For long items that cannot be stored efficiently on Euro pallets, Jungheinrich has also installed 135 cantilever storage locations. These are served by electric counterbalance trucks.
One control system for two material flows
The key technical feature of the installation is the shared control architecture. The Jungheinrich Warehouse Control System coordinates both the movements within the PowerCube and the transport processes in the VNA warehouse.
According to Jungheinrich, Deutsche Aircraft is the first customer to use PowerCube and AutoVNA in this combination. The setup physically separates the storage of smaller parts from larger components while integrating both material flows within a single control system.
Logistics for up to 48 D328eco aircraft per year
The logistics center is part of Deutsche Aircraft’s new Factory 4.0 at Leipzig/Halle Airport. The company has established a digitally connected and paperless final assembly line for the D328eco at the site. According to Deutsche Aircraft, the facility is also intended to operate on a carbon-neutral basis.
The intralogistics system is designed to support the planned production ramp-up. Deutsche Aircraft is targeting capacity of up to 48 aircraft per year at Leipzig/Halle. Production is initially designed for two-shift operation and can be expanded to three shifts.
At full capacity, the site is expected to employ between 250 and 350 people. Leipzig/Halle will therefore become the industrial center of the D328eco program.