MRO & Manufacturing
Collins Aerospace Cuts Aircraft Wheel Production to Seven Days
Collins Aerospace in Troy, Ohio reduced aircraft wheel manufacturing time from 45 to seven days with a new automated multitask machining cell.

This article is based on an official press release and company reporting from Collins Aerospace.
From WWII Gliders to “Wheels in a Week”: The Manufacturing Revolution at Collins Aerospace
In Troy, Ohio, a factory with deep roots in aviation history is undergoing a radical transformation. The facility, once known for producing the gliders that carried troops into World War II battles, has successfully implemented a new manufacturing initiative dubbed “Wheels in a Week.” According to Collins Aerospace, this program has slashed the production time for aircraft wheels by approximately 80 percent, reducing a 45-day process to just seven days.
The centerpiece of this efficiency drive is a new automated production cell described by the company as “tall and sleek, bigger than a phone booth but smaller than a passenger elevator.” This modernization effort highlights a broader shift within the aerospace sector, moving from traditional, fragmented machine shops to integrated, high-tech “Industry 4.0” environments.
A Historic Facility Reimagined
The Troy facility holds a significant place in American aviation heritage. Originally the home of the Waco Aircraft Company, the site was the largest manufacturer of civil aircraft in the United States during the late 1920s and early 1930s. During the Second World War, the factory pivoted to produce CG-4A gliders, which were essential for transporting heavy equipment and troops into combat zones.
Today, the site serves as a critical hub for Collins Aerospace, a Raytheon Technologies (RTX) business. While the brick-and-mortar backdrop remains, the interior operations have evolved. The “Wheels in a Week” initiative represents the latest chapter in this evolution, aiming to address the logistical challenges of modern aerospace manufacturing.
The “Wheels in a Week” Initiative
Historically, manufacturing an aircraft wheel at the Troy plant was a disjointed process. According to company reports, a single wheel would travel through five different legacy machines. This workflow required manual transport, setup, and handling at each stage, resulting in a production timeline of approximately 45 days from raw forging to finished part.
The new initiative sought to compress this timeline drastically. By consolidating these steps, Collins Aerospace reports that they have met their ambitious goal of a seven-day turnaround.
“Cutting time by 10 percent, that’s something we’re going to go do. Cutting it by 80 percent? That is a monumental effort that’s going to require all of us together to make it successful.”
, Greg Smith, Director of Operations, Collins Aerospace (Troy, OH)
Technological Consolidation
The reduction in lead time is largely attributed to the introduction of a multitask machining center. Described in company materials as having “white walls and red doors,” this machine performs both lathe work (spinning and turning) and mill work (cutting and grinding) in a single setup.
Previously, these tasks required five separate machines. The new automated cell features a pallet-changing system that loads and unloads parts without human intervention inside the machine. This consolidation eliminates the “white space”, or idle time, that occurred when parts were moved between stations.
Impact on Safety and Flexibility
Beyond speed, the automation has introduced significant safety improvements. By removing the need for workers to manually lift and fixture heavy wheel forgings multiple times, the physical strain on operators is reduced. The role of the workforce has subsequently shifted from manual labor to technical oversight, involving programming and monitoring of the automated cells.
Troy Brunk, President of Collins Aerospace, emphasized the strategic value of this flexibility in a company statement.
“Taking 45 days of lead time down to seven creates more flexibility for us and our customers. When we think big, we can do a lot of things.”
, Troy Brunk, President, Collins Aerospace
The ability to switch between different wheel models rapidly allows the factory to handle smaller batches and urgent orders more effectively, a crucial capability in a supply chain often beset by fluctuations in demand.
AirPro News Analysis
The success of the “Wheels in a Week” program at Collins Aerospace illustrates a critical trend in the aerospace supply chain: the necessity of resilience through speed. By reducing lead times by 80 percent, manufacturers do not just save money; they insulate themselves against upstream disruptions. When a production cycle takes 45 days, a raw material delay is a crisis. When it takes seven days, the system can recover and pivot much faster.
Furthermore, the cultural shift mentioned by Scott Parkin, VP of Operations for Advanced Structures, suggests that the barrier to modernization is often as much about mindset as it is about machinery. The transition from a “grime and grease” shop to a clean, automated facility requires buy-in from the workforce, proving that Industry 4.0 is as much a human resources challenge as a technological one.
Sources
Sources: Collins Aerospace / RTX
Photo Credit: RTX
MRO & Manufacturing
I Squared Capital Acquires Orizon Aerostructures for $2 Billion
I Squared Capital agrees to acquire Orizon Aerostructures in a ~$2B deal, targeting F-35 and 737 MAX supplier capacity.

Global infrastructure investor I Squared Capital has entered into a definitive agreement to acquire aerospace manufacturer Orizon Aerostructures in a transaction reportedly valued at approximately $2 billion. The acquisition, announced on October 28, 2026, aims to inject capital into essential industrial infrastructure to alleviate ongoing aerospace supply chain constraints.
The deal targets a critical node in the manufacturing ecosystem for major commercial and defense programs, including the Lockheed Martin F-35 Lightning II and the Boeing 737 MAX. According to a press release issued by I Squared Capital, Orizon’s founders and senior management will reinvest a meaningful equity portion and continue to lead the company following the transaction’s expected close in the fourth quarter of 2026.
Expanding manufacturing capacity amid supply chain constraints
The global aerospace industry is currently facing severe supply chain constraints. This pressure is driven by a commercial aircraft order backlog that exceeded 18,000 units as of June 2026, according to data from the International Air Transport Association (IATA). Concurrently, rising defense spending and the expansion of space infrastructure have intensified the demand for specialized manufacturing capacity.
Years of underinvestment have left major original equipment manufacturers (OEMs) reliant on ready-to-run suppliers with established machining centers and certifications. This dynamic has prompted private equity firms and strategic buyers to acquire seasoned vendors to alleviate production chokepoints.
Gautam Bhandari, Managing Partner and Chief Investment Officer at I Squared Capital, highlighted the necessity of supporting the lower tiers of the aerospace manufacturing base.
Expanding aircraft production requires investment in essential industrial infrastructure throughout the supply chain. Orizon provides a critical part of that infrastructure: highly specialized production capacity deeply embedded in aircraft programs that span decades.
Orizon’s growth and defense program integration
Founded in 2016 by brothers Charlie and Henry Newell, Orizon Aerostructures manufactures large, complex structural components and subassemblies for commercial aviation, defense, and space applications. Headquartered in Kansas City, Missouri, the company operates five facilities across Kansas and Oklahoma, employing over 900 highly skilled workers.
The manufacturer expanded its footprint partly through the acquisition of existing production facilities, including a former Spirit AeroSystems site in Chanute, Kansas. To support this growth, American Industrial Partners invested $50 million into Orizon Aerostructures on December 28, 2020.
The company has since secured its position as a key supplier for major aerospace platforms. On June 16, 2025, Orizon Aerostructures signed a Strategic Collaboration Agreement with Lockheed Martin Corporation at the Paris Air Show. The following day, on June 17, 2025, Orizon announced a multiyear follow-on contract for the Lockheed Martin F-35 Lightning II program. This agreement pushed the company’s backlog past $3.1 billion.
Charlie Newell, Co-Founder and Chief Executive Officer, and Henry Newell, Co-Founder and President, outlined their original vision for the manufacturer in the acquisition announcement.
Our goal with Orizon was to build something unique. For us, that meant an organically grown, vertically integrated business which could machine, process and assemble the industry’s most complex parts and subassemblies with advanced manufacturing technology to solve our customers’ biggest problems.
Infrastructure investment strategy
Founded in 2012 and headquartered in Miami, Florida, I Squared Capital is an independent global infrastructure investor managing over $60 billion in assets. The firm traditionally focuses on mid-market investments across power, utilities, transport, logistics, and digital infrastructure, maintaining a portfolio of over 100 companies operating in more than 70 countries.
The acquisition of an aerospace parts manufacturer represents a specific strategic view of the aerospace supply chain as a form of industrial infrastructure. Bhandari noted that Orizon possesses the financial and operational characteristics the firm targets.
Its exclusive, life-of-program contracts, cost pass-through provisions and demanding qualification requirements combine long-term customer relationships with significant barriers to entry—the attributes we seek as infrastructure investors.
While the official press release from I Squared Capital stated that the financial terms of the transaction were not disclosed, financial media outlets, citing Bloomberg, reported that the deal values Orizon Aerostructures at approximately $2 billion. The transaction remains subject to customary closing conditions and regulatory approvals.
AirPro News analysis
The acquisition of Orizon Aerostructures by an infrastructure fund rather than a traditional private equity buyout firm or a strategic aerospace buyer highlights a shift in how capital markets view the aerospace supply chain. Infrastructure investors typically seek assets with high barriers to entry, monopolistic characteristics, and predictable, long-term cash flows, such as toll roads, ports, and utility networks. By classifying a Tier 2 aerospace structures supplier as “essential industrial infrastructure,” I Squared Capital is signaling that established machining capacity and OEM certifications are now viewed as scarce, infrastructure-like assets.
With major OEMs like The Boeing Company struggling to ramp up production rates due to supplier chokepoints, companies that possess ready-to-run facilities, skilled labor, and life-of-program contracts hold significant pricing power and stability. Orizon’s $3.1 billion backlog and integration into decades-long programs like the F-35 Lightning II provide the revenue visibility that infrastructure funds require, potentially paving the way for similar reclassifications of critical aerospace suppliers by large-cap investment firms.
Photo Credit: I Squared Capital
MRO & Manufacturing
Panasonic Technical Services Opens First MRO at Western Sydney Airport
Panasonic Technical Services opens the first MRO facility at Western Sydney International Airport, expanding its network to 14 locations.

Panasonic Technical Services has established the first maintenance, repair, and overhaul (MRO) facility at the newly opened Western Sydney International Airport (WSI), expanding its global Technical Ground Handling network to 14 locations.
Announced in an October 27, 2026 press release by parent company Panasonic Avionics Corporation, the facility marks a strategic evolution for the provider as it broadens its traditional in-flight entertainment and connectivity (IFEC) maintenance into comprehensive aircraft line maintenance for anchor customers such as Qantas Freight.
Establishing operations at Western Sydney International
Western Sydney International Airport officially opened to commercial passenger flights on October 25, 2026. The facility is Australia’s first major new airport in more than 50 years and operates as a 24-hour, curfew-free aviation hub.
By establishing operations during the airport’s opening stages, Panasonic Technical Services (PTS) secured a first-mover advantage. The MRO provider recruited and trained personnel, obtained Civil Aviation Safety Authority (CASA) Part 145 approvals, and deployed necessary tooling to support early operators. The WSI operation is designed to be scalable to support future airline requirements as airport activity develops.
The facility initially supports Qantas Freight. The cargo operator commenced domestic flights at the airport in July 2026, utilizing Airbus A321P2F and Airbus A330 aircraft to take advantage of the curfew-free operating environment.
Tom Eskola, Vice President of Panasonic Technical Services at Panasonic Avionics, highlighted the strategic placement of the new site.
“Western Sydney International is a strong example of this model in action. We were the first MRO provider to establish onsite operations, giving our customers access to aircraft maintenance from the airport’s earliest stages,” Eskola said.
Evolution of Panasonic’s maintenance capabilities
Headquartered in Irvine, California, Panasonic Avionics Corporation employs over 3,300 people globally and is primarily known as a supplier of IFEC systems. Its PTS subsidiary brings 30 years of maintenance experience to the market and operates a wider global network encompassing approximately 50 line maintenance stations and eight repair stations, each operating within applicable regulatory approvals.
Historically, PTS focused strictly on maintaining the company’s proprietary IFEC hardware. The expansion of its Technical Ground Handling division represents a shift toward broader aircraft support. The 14 locations within this specific network now offer Transit, Extended-range Twin-engine Operations Performance Standards (ETOPS), Daily, and Weekly checks.
The WSI facility follows recent network expansions, including the September 2026 addition of line maintenance support for China Airlines (CI) Boeing 777 services in Seattle.
Eskola noted that airline customers require technical support capable of scaling with their route networks. Reaching 14 Technical Ground Handling locations across three continents reflects how the company is evolving to meet that demand by combining a local presence with the scale and expertise delivered across its network.
AirPro News analysis
Securing first-mover status at a 24-hour, curfew-free airport like Western Sydney International is a highly strategic play for an MRO provider. Cargo aircraft operators such as Qantas Freight rely on high dispatch reliability and rapid turnaround times, making immediate access to onsite line maintenance critical. For Panasonic Avionics, the pivot from a niche IFEC maintenance provider to a comprehensive line maintenance organization demonstrates a clear push to capture a larger share of its airline customers’ operational spend. By leveraging its existing global footprint of IFEC technicians and upgrading their certifications to handle broader airframe checks, the company is positioning itself as a direct competitor to traditional independent line maintenance providers.
Photo Credit: Panasonic Avionics Corporation
MRO & Manufacturing
Airbus FHS Contract Covers 400 A220s for Lufthansa Group
Airbus FHS now supports 400+ A220s globally after adding SWISS, ITA Airways, and Lufthansa City Airlines to its power-by-the-hour program.

Airbus SE has detailed a comprehensive Flight Hour Services (FHS) component support contract covering the Airbus A220 fleets of three Lufthansa Group-affiliated carriers, bringing the total number of A220s maintained under the manufacturer’s proprietary power-by-the-hour model to more than 400 aircraft globally.
The agreement, highlighted in an operational briefing published by Airbus on October 29, 2026, provides integrated maintenance and parts support for Swiss International Air Lines (SWISS), Italia Trasporto Aereo S.p.A. (ITA Airways), and the newly formed Lufthansa City Airlines. The contract ensures that over 70 percent of the active global A220 fleet is now supported directly by the European aerospace corporation’s material management division.
Expanding the power-by-the-hour footprint
The Airbus FHS division provides an integrated, performance-based material management model designed to streamline airline maintenance operations. Under the FHS structure, operators pay a fixed rate per flight hour. In exchange, Airbus guarantees component availability, manages logistics and repairs, and provides access to a shared global inventory of certified spare parts.
By pooling components globally, the power-by-the-hour model shifts the capital expenditure of spare parts inventory from the airline to the Original Equipment Manufacturer (OEM). This structure is designed to reduce the risk of Aircraft On Ground (AOG) events, where flights are canceled or delayed due to missing parts.
Instead of an airline carrying the heavy financial burden of purchasing and warehousing millions of dollars in spare parts across multiple airports, FHS ensures certified parts are positioned at critical hubs around the globe.
The inclusion of the Lufthansa Group carriers expands the reach of the Airbus FHS program significantly. According to the manufacturer, the service now supports over 1,800 aircraft globally across almost 60 operators. For the A220 program specifically, 12 airlines currently operate the type under the FHS model.
In an official statement regarding the agreement, Airbus noted the historical ties with the operators involved. “We are honored to be chosen to renew our support for SWISS and extend our long-running partnership to ITA Airways and Lufthansa City Airlines,” the company stated.
Lufthansa Group’s growing A220 reliance
The component services agreement covering the three carriers was initially signed during the ILA Berlin air show in June 2026. The deal underscores the Lufthansa Group’s increasing reliance on the A220 platform for its short-haul and feeder network operations.
The Airbus A220, originally developed by Bombardier as the CSeries before Airbus acquired a majority stake in the program in 2018, has a long history within the Lufthansa Group. SWISS served as the global launch customer for the smaller Airbus A220-100 variant, which entered commercial service in July 2016. ITA Airways also operates a growing fleet of both A220-100s and Airbus A220-300s across its domestic and European networks.
The newest operator under the contract, Lufthansa City Airlines, is currently preparing to induct its first aircraft. The Lufthansa Group placed a firm order for 40 A220-300s for the new short-haul feeder carrier in December 2023. The first of these aircraft, designated as MSN 55501, is undergoing final assembly at the Airbus Canada facility in Mirabel, Quebec, and is scheduled for delivery in November 2026.
Production targets and market context
The operational briefing on the FHS contract follows closely on the heels of the manufacturer’s latest financial disclosures. On October 28, 2026, Airbus released its nine-month 2026 financial results, confirming that the company delivered 68 A220 aircraft during the first three quarters of the year.
During the financial update, Airbus reaffirmed its production ramp-up targets for the narrowbody program. The manufacturer is progressing toward a targeted monthly production rate of 13 A220 aircraft across its assembly lines by 2028.
As the global fleet expands to meet these production targets, the demand for integrated component support is expected to scale accordingly. By securing maintenance contracts for the majority of the in-service fleet, Airbus ensures that its logistics hubs and component pools are positioned to support the higher volume of flight hours generated by new deliveries.
AirPro News analysis
Securing over 70 percent of the active A220 fleet under its own FHS umbrella gives Airbus a dominant position in the aftermarket revenue stream for this specific aircraft type. As the A220 production rate ramps up toward the 2028 target of 13 aircraft per month, maintaining a tight grip on component support ensures long-term profitability for the OEM well beyond the initial point of sale. The power-by-the-hour model effectively locks operators into the Airbus ecosystem for the lifecycle of the airframe.
For the Lufthansa Group, pooling spares across three distinct operating certificates provides economies of scale that would be highly inefficient to replicate internally. Managing separate spare parts inventories for SWISS in Zurich, ITA Airways in Rome, and Lufthansa City Airlines in Germany would require massive capital expenditure. By outsourcing this to Airbus, the airline group standardizes its maintenance costs into predictable hourly operating expenses, a critical advantage as it scales up its new regional subsidiary.
Photo Credit: Airbus
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