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.
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.
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.
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)
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.
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.
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: Collins Aerospace / RTX
From WWII Gliders to “Wheels in a Week”: The Manufacturing Revolution at Collins Aerospace
A Historic Facility Reimagined
The “Wheels in a Week” Initiative
Technological Consolidation
Impact on Safety and Flexibility
AirPro News Analysis
Sources
Photo Credit: RTX
MRO & Manufacturing
Korean Air and Busan Invest 200 Billion Won in Aerospace Facility
Korean Air and Busan commit 200 billion won to build a new aerospace plant for UAVs, aircraft parts, and military upgrades in Busan.
This article summarizes reporting by ChosunBiz. The original report may be subject to premium access; this article summarizes publicly available elements and public remarks.
Korean Air Lines and the City of Busan have officially signed a Memorandum of Understanding (MOU) for a 200 billion won (approximately $150 million USD) investment to construct a new drone and aerospace manufacturing facility. According to reporting by ChosunBiz on March 30, 2026, this agreement marks the largest aerospace investment the city has ever attracted.
The new plant will be situated within Korean Air’s existing Busan Tech Center in the Gangseo District. It is designed to serve as a multipurpose hub, focusing on next-generation commercial aircraft components, military aircraft upgrades, and advanced unmanned aerial vehicles (UAVs).
This development aligns with Busan’s strategic vision to establish a “Future Aviation Cluster” connected to the upcoming Gadeokdo New Airport, positioning the region as a central player in the global aerospace supply chain.
The planned facility will significantly expand Korean Air’s manufacturing footprint. Based on industry research data, the new plant will feature a total floor area of 52,892 square meters and will be constructed on a 36,363-square-meter idle site within the current Tech Center grounds. The existing Busan Tech Center, established in 1976, already covers an expansive 717,359 square meters and is recognized as Asia’s largest military aircraft maintenance facility.
The multipurpose plant will focus on three primary operational pillars: manufacturing AI-powered UAVs, producing structural components for next-generation civil aircraft, and conducting maintenance, repair, overhaul, and upgrade (MROU) services for military aircraft.
The signing ceremony was attended by key regional and corporate leaders, including Busan Mayor Park Heong-joon and Korean Air Lines Vice Chairman and CEO Woo Kee-Hong. During the event, corporate leadership emphasized the forward-looking nature of the project.
“This investment is a strategic decision to lead the global unmanned aircraft market and secure capabilities for next-generation aircraft manufacturing,” stated Woo Kee-Hong, Vice Chairman and CEO of Korean Air Lines.
Mayor Park emphasized the city’s commitment to the project, noting in public remarks that Busan will provide administrative and financial backing to ensure Korean Air serves as the anchor for the region’s future aviation cluster. While globally recognized as a commercial passenger airline, Korean Air operates as South Korea’s only fully integrated aerospace company. According to industry background data, the company has been manufacturing aircraft parts since 1977, supplying major aerospace firms like Boeing and Airbus with components such as 787 Dreamliner parts and A350 cargo doors.
The Aerospace Business Division has recently proven to be a highly profitable segment for the airline. This success is partly driven by substantial defense contracts, including a reported 1 trillion won project to upgrade UH-60 Black Hawk helicopters for the South Korean military.
Korean Air is aggressively expanding its footprint in the drone and artificial intelligence sectors. At the “Drone Show Korea 2026” held in Busan in late February, the company unveiled South Korea’s first physical AI-powered subsonic UAV, developed alongside U.S. defense technology firm Anduril Industries. Furthermore, the airline has made strategic investments in Pablo Air, a domestic startup specializing in swarm AI drone technology.
In the realm of Advanced Air Mobility (AAM), Korean Air is laying the groundwork for commercial air taxis. The company has partnered with Skyports for vertiport development and holds an exclusive arrangement to operate up to 100 “Midnight” eVTOL aircraft from Archer Aviation.
We view this 200 billion won investment as a critical physical manifestation of Korean Air’s strategy to diversify its revenue streams. By building a robust defense and technology portfolio, the airline is actively insulating itself from the traditional volatilities of the passenger travel market, such as fluctuating oil prices and exchange rates.
Furthermore, the timing of this MOU coincides with strong governmental backing for the sector. In March 2026, the Korea Aerospace Administration (KAA) announced a 200 billion won “New Space Fund” to support domestic aerospace companies. Korean Air’s expansion in Busan perfectly positions the company to capitalize on both regional infrastructure developments, like the Gadeokdo New Airport, and national strategic funding initiatives.
Korean Air is investing 200 billion won (approximately $150 million USD) in the new facility, marking the largest aerospace investment in Busan’s history.
The plant will be built on an idle 36,363-square-meter site within Korean Air’s existing Busan Tech Center in the Gangseo District. The plant will serve as a multipurpose hub to manufacture next-generation commercial aircraft parts, upgrade military aircraft, and produce future AI-powered unmanned aerial vehicles (UAVs).
Facility Specifications and Strategic Objectives
Expanding the Busan Tech Center
Leadership Perspectives
Korean Air’s Broader Aerospace Ambitions
Beyond Passenger Aviation
The Push into AI and Advanced Air Mobility
Market Context and Outlook
AirPro News analysis
Frequently Asked Questions
How much is Korean Air investing in the new Busan plant?
Where will the new aerospace plant be located?
What will the new facility produce?
Sources
Photo Credit: News1
MRO & Manufacturing
Helicopter Services Secures Three Airbus H125s for 2026 Delivery
Helicopter Services, Inc. pre-purchases three Airbus H125 helicopters for 2026 to offer turn-key solutions amid supply delays, following a custom delivery to GCI Communications in Alaska.
This article is based on an official press release from Helicopter Services, Inc.
In a strategic move to bypass ongoing aerospace supply chain delays, Texas-based Helicopter Services, Inc. (HSI) has announced the acquisition of three Airbus H125 helicopters scheduled for delivery in 2026. According to the company’s March 16, 2026, press release, these aircraft are being procured in advance to offer operators turn-key, mission-ready solutions without the standard manufacturer wait times.
The announcement follows closely on the heels of a major milestone for the maintenance, repair, and overhaul (MRO) provider: the mid-2025 delivery of a highly customized Airbus H125 to GCI Communications, Alaska’s largest telecommunications provider. That delivery underscored HSI’s growing footprint in specialized utility completions, outfitting aircraft for some of the most extreme environmental conditions in North America.
By securing these 2026 delivery positions, HSI aims to target operators across diverse sectors, including public safety, mosquito abatement, utility operations, aerial firefighting, and VIP transport. We are seeing a distinct trend where completion centers are taking on procurement risks to guarantee availability for their end-users.
According to the official announcement, HSI’s purchase of the three Airbus H125s is designed to streamline the acquisition process for its clients. Rather than an operator ordering a green aircraft from Airbus and waiting for production and subsequent outfitting, HSI will receive the aircraft directly and perform custom completions in-house.
Company leadership emphasized that this approach directly addresses the needs of operators who require immediate operational readiness.
“Securing these delivery positions allows HSI to better support operators seeking the proven performance and versatility of the Airbus H125. HSI is pleased to continue strengthening our relationship with Airbus Helicopters.”
Mike Crossland, General Manager, HSI
We view HSI’s decision to pre-purchase inventory as a notable strategic shift within the helicopter completion and MRO industry. Historically, completion centers waited for clients to procure their own aircraft before beginning customization work. By securing these three H125s, HSI is effectively acting as a specialized dealer. In a market where supply chain bottlenecks continue to hinder critical public safety and utility operations, offering a ready-to-fly, customized helicopter is a significant competitive advantage. This model is highly lucrative when applied to niche markets like aerial spraying or heavy-lift utility, where mission-specific outfitting is mandatory. The 2026 acquisition strategy is built upon HSI’s recent successes in complex utility completions. In mid-2025, the company delivered a custom-completed H125 to GCI Communications. According to project details released by HSI, the aircraft was specifically tailored to support GCI’s TERRA network.
Data provided in the company’s release notes that the TERRA network delivers internet and cellular service to 84 rural communities across Alaska. The infrastructure relies on 22 remote, self-sufficient towers. Because these sites are inaccessible by road, they require annual refueling via helicopter. HSI reports that the operation involves transporting over 110,000 gallons of diesel fuel annually to keep the network online.
To meet the rigorous demands of heavy utility work in freezing, remote terrain, HSI outfitted the GCI helicopter with several specialized components. According to the release, modifications included an advanced autopilot system, an Onboard Systems cargo hook designed for heavy external loads, and a DART Vertical Reference Floor Window, which provides pilots with enhanced downward visibility during precision long-line flying.
“GCI is a new client for Helicopter Services, Inc. They are the largest communications provider in Alaska and we outfitted their new H125 to meet operational demands and environmental conditions in which it will be flying.”
Ali Durham, Project Manager, HSI
The choice of the Airbus H125 for both the GCI delivery and the 2026 bulk order is rooted in the aircraft’s industry standing.
Formerly known as the AS350 B3e, the Airbus H125 is widely recognized as the leader in the single-engine helicopter market. Industry specifications highlight that it accounts for over 75% of all single-engine law enforcement deliveries in North America. Powered by a Safran Arriel 2D engine, the H125 boasts a maximum cruise speed of 137 to 140 knots and a range of approximately 340 nautical miles. Its utility capabilities are anchored by a sling capacity of 1,400 kg (3,086 lbs), making it highly effective for the external load lifting required by clients like GCI.
Founded in 1980 and based at the David Wayne Hooks Memorial Airport in Spring, Texas, HSI has steadily expanded its capabilities. According to company background data, HSI is an FAA Part 145 Certified Repair Station and holds the unique distinction of being the only company on the U.S. General Services Administration (GSA) marketplace focused solely on the helicopter industry.
To support its growing roster of clients, which includes the Houston Police Department and various municipal mosquito control districts, HSI expanded its facility in May 2025. The expansion increased their footprint to over 25,000 square feet, adding dedicated shop areas for sheet metal, composites, and avionics to handle the increased demand for MRO and air medical completions. Why is Helicopter Services, Inc. buying helicopters in advance? What is the Airbus H125 used for? What customizations were made for the GCI Communications helicopter?
Helicopter Services, Inc. Secures Three Airbus H125s for 2026, Following Major Telecom Delivery
Proactive Procurement for 2026 Deliveries
AirPro News analysis
Conquering Alaskan Extremes with GCI Communications
The TERRA Network Mission
Customizing for the Cold
The Airbus H125 and HSI’s Growing Footprint
The H125 Workhorse
HSI Facility Expansion
Frequently Asked Questions
According to HSI, pre-purchasing aircraft allows the company to bypass standard manufacturer wait times. This enables them to offer clients fully customized, turn-key helicopters much faster than traditional procurement methods.
The Airbus H125 is a versatile single-engine helicopter used heavily in public safety, utility operations, aerial firefighting, and VIP transport. It is particularly noted for its high-altitude performance and heavy external sling capacity (up to 3,086 lbs).
To support remote telecom tower refueling in Alaska, HSI equipped the GCI helicopter with an autopilot system, a DART Vertical Reference Floor Window for precision flying, and an Onboard Systems cargo hook for heavy utility lifting.
Sources:
Photo Credit: Helicopter Services, Inc.
MRO & Manufacturing
EU and India Sign Aviation Production Working Arrangement in 2026
The EU and India agreed to align aerospace manufacturing standards, enabling Airbus H125 helicopter assembly in Karnataka by 2026.
On March 23, 2026, the European Union and India signed a landmark Working Arrangement to deepen cooperation in industrial aviation production. Officially announced on March 27, the agreement between the European Union Aviation Safety Agency (EASA) and India’s Directorate General of Civil Aviation (DGCA) aims to align Indian aerospace manufacturing with global safety standards.
According to the official press release and accompanying research, a central pillar of this pact is the support for India’s “Make in India” initiative. Specifically, the arrangement facilitates the assembly of Airbus H125 helicopters in Karnataka under stringent EU standards, marking a significant step in localizing aviation production and strengthening strategic aerospace ties between the two regions.
We at AirPro News view this development as a critical milestone in the long-standing strategic partnership between the EU and India, directly building upon commitments made during the EU-India Summit in January 2026, where civil aviation safety was identified as a high-priority focus area.
The core objective of the newly signed agreement is to support industrial cooperation by ensuring domestic manufacturing practices in India align with European norms. The EEAS press release highlights that this regulatory harmonization will make global market access easier for Indian aerospace products, ensuring that safety and sustainability remain central to the rapid growth of the aviation sector.
The most prominent project enabled by this working arrangement is the final assembly of Airbus H125 helicopters. According to industry research, India’s first private-sector helicopter Final Assembly Line (FAL) has been established by Tata Advanced Systems Limited (TASL) in partnership with Airbus at the Vemagal Industrial Area in Karnataka’s Kolar district.
The facility, which was virtually inaugurated in February 2026 by Indian Prime Minister Narendra Modi and French President Emmanuel Macron, is expected to become operational in April 2026. Production timelines indicate that the first “Made in India” H125 helicopter is projected for delivery in early 2027. The H125 is recognized as the world’s best-selling single-engine helicopter, known for its ability to operate in extreme, high-altitude environments.
The signing of the working arrangement preceded the EU-South Asia Aviation Partnership Project Workshop, held in New Delhi from March 24 to 26, 2026. Organized by EASA in close cooperation with the DGCA and supported by European turboprop manufacturer ATR, the workshop focused on strengthening practical collaboration and addressing day-to-day flight operations across the South Asian region. By aligning with the 27-member bloc’s safety standards, India is positioning itself as a key exporter in the aerospace sector. The Karnataka facility is expected to serve not only the domestic market but also export to the broader South Asian region.
“Aligning Indian production with the 27-member bloc’s safety standards and export certificates will help deliver aircraft products manufactured in India to the global market,” noted EU Ambassador Hervé Delphin, according to the provided research report.
We assess that this working arrangement represents a landmark step toward self-reliance in aerospace and defense for India. By localizing the assembly of critical aerospace assets, India is significantly expanding its manufacturing ecosystem, following the previous Tata-Airbus joint venture for the C-295 military transport aircraft in Gujarat.
Furthermore, the mutual commitment to safe, resilient, and sustainable air transport underscores the increasing operational and environmental challenges facing the global aviation industry. The integration of EU safety standards will likely bolster supply chain resilience for both regions while opening new avenues for military and civil aviation logistics.
It is an agreement signed on March 23, 2026, between the European Union Aviation Safety Agency (EASA) and India’s Directorate General of Civil Aviation (DGCA) to align Indian aerospace manufacturing with European safety standards.
According to industry timelines, the Tata-Airbus facility is expected to become operational in April 2026, with the first helicopter delivery anticipated in early 2027.
Harmonizing Regulatory Frameworks
The Airbus H125 Project in Karnataka
Regional Collaboration and Export Potential
Expanding Global Reach
AirPro News analysis
Frequently Asked Questions
What is the EU-India Working Arrangement on Industrial Aviation Production?
When will the Airbus H125 facility in Karnataka become operational?
Sources
Photo Credit: The CSR Journal
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