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Avio Aero Pomigliano Cuts Lead Times 42% With FLIGHT DECK

GE Aerospace’s Avio Aero plant in Italy cut lead times and inventory costs 42% using its FLIGHT DECK lean operating model.

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By applying a proprietary lean operating model to its shop floor, GE Aerospace’s Avio Aero plant in Pomigliano d’Arco, Italy, cut component lead times and inventory costs by 42 percent across its most critical production lines.

The company announced the operational metrics on July 30, 2026, alongside news that the facility received the 2026 Altitude Award for Site Breakthrough. The Pomigliano site manufactures approximately 3,000 individual components for commercial and military engines, supporting high-demand programs such as the GE9X, the Eurojet EJ200, and the LEAP engine produced by CFM International, a 50-50 joint company between GE Aerospace and Safran Aircraft Engines.

Mapping and eliminating production waste

The facility’s transition to lean management formally began in 2018, five years after GE Aerospace acquired Avio Aero. The initiative accelerated in 2022 under the direction of Site Leader Roberto Bertaina. Upon his arrival, Bertaina and his team mapped the existing production journey for stator vanes, discovering a highly circuitous routing path that Bertaina described as a “spaghetti diagram.”

To resolve these inefficiencies, the team targeted the programs where they could drive the most immediate impact. They identified redundant processes, such as performing four separate grinding operations on certain parts, and reduced them to two sequenced, linear steps.

“We had parts moving round the shop to different machines, and different parts coming to the same machine. That generated waste in terms of waiting, because the same machine operator was prioritizing one workflow over another,” Bertaina stated in the company release.

Measurable gains in engine component manufacturing

The application of GE Aerospace’s FLIGHT DECK lean operating model yielded substantial improvements on 12 key ramp-up production lines. In addition to the 42 percent reduction in both lead time and inventory costs, the targeted lines saw a 20 percent increase in labor productivity. These metrics directly improved the facility’s ability to meet takt time, ensuring component output aligns with customer demand.

The shop floor now features 15 control centers equipped with screens and audio systems to facilitate real-time collaboration. According to the company, the Pomigliano team currently manages approximately 60 active problem-solving efforts to continuously refine safety, quality, delivery, and cost.

Bertaina noted that the facility is on track to double its conversion speed compared with 2022 baselines, which previously suffered from several weeks of delinquency on certain lines.

AirPro News analysis

The operational turnaround at the Pomigliano facility highlights a broader industry imperative. As aerospace original equipment manufacturers push to increase production rates, supply chain bottlenecks at the component level remain a primary constraint. By embedding lean principles directly onto the shop floor, GE Aerospace is addressing these constraints at the source. We view the formalization of the FLIGHT DECK model not just as an internal efficiency exercise, but as a necessary strategy to stabilize the supply base for high-volume programs like the CFM LEAP. When tier-level suppliers and subsidiary plants can predictably meet takt time, the entire final assembly line benefits from reduced disruption.

Sources: GE Aerospace

Photo Credit: GE Aerospace

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MRO & Manufacturing

Vietjet and Thales Sign MRO and Digital Aviation Agreements

Vietjet and Thales finalized a Repair-By-The-Hour maintenance contract and an AI and cybersecurity MoU in September 2026.

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Vietjet Aviation Joint Stock Company (Vietjet) and Thales Group have finalized a long-term component maintenance agreement and a digital transformation pact, securing aftermarket support for the carrier’s expanding Airbus fleet while integrating artificial intelligence and cybersecurity into its operations.

In a press release issued on September 15, 2026, Thales announced that the “Repair-By-The-Hour” (RBTH) contract and a concurrent Memorandum of Understanding (MoU) were signed on September 10, 2026. The signing took place at the Élysée Palace in Paris during a Vietnamese state delegation visit, overseen by French President Emmanuel Macron and Vietnamese General Secretary and President To Lam.

Maintenance and fleet support

The RBTH contract provides Vietjet with long-term component maintenance services covering its Airbus A320 family and Airbus A330 family aircraft. The agreement is designed to optimize fleet availability and lower operational lifecycle costs as the Airlines scales its flight schedule to meet regional and international demand.

Vietjet has recorded substantial operational growth throughout the year. According to reporting by TechNode Global, the airline generated consolidated revenue of VND51.54 trillion ($2 billion) in the first half of 2026, representing a 44 percent year-over-year increase. During that six-month period, Vietjet carried 13.4 million passengers across approximately 72,000 flights.

The Thales agreement is part of a broader procurement and maintenance strategy executed during the September 2026 state visit. TTR Weekly reported that Vietjet also signed a Letter of Intent with CFM International to assess engine support and maintenance capabilities, further solidifying its European aerospace supply chain.

Digital aviation and cybersecurity

Alongside the maintenance contract, the two companies signed an MoU focused on digital aviation. The agreement outlines cooperation in connectivity, cybersecurity, and AI applied directly to airline operations. The initiative aims to protect critical aviation systems while advancing the carrier’s digital transformation.

Thales brings established regional infrastructure to the partnership. The technology firm has maintained a corporate presence in Vietnam for 30 years and currently employs a workforce that includes 800 AI experts.

“Our partnership with Thales will not only enhance the reliability, safety and operational efficiency of Vietjet’s fleet, but also open up new areas of cooperation in digital technology, AI and cybersecurity,” said Nguyen Thanh Son, CEO of Vietjet. “Together with leading French partners, we look forward to connecting technological expertise with a dynamic aviation market, contributing to stronger trade, investment and ties between Vietnam and France.”

Pascale Sourisse, CEO of Thales International, stated that the company intends to support the airline’s next phase of growth through advanced technology and operational excellence.

Bilateral aerospace cooperation

The finalized contracts reinforce the Comprehensive Strategic Partnership established between France and Vietnam in October 2024. That diplomatic framework explicitly identified aviation as a key pillar of bilateral cooperation, paving the way for state-backed commercial agreements between Vietnamese operators and French aerospace Manufacturers.

AirPro News analysis

We view Vietjet’s concurrent agreements with European aerospace firms as a calculated move to stabilize its operational foundation amid rapid network expansion. By locking in long-term, predictable MRO costs through the Thales RBTH contract and the CFM International engine support assessment, the carrier is mitigating the Supply-Chain volatility that has constrained global fleet availability. The formal integration of cybersecurity and AI initiatives indicates a maturation of Vietjet’s operational infrastructure, aligning its technological capabilities with its high-growth financial trajectory.

Sources: Thales Group

Photo Credit: Thales Group

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MRO & Manufacturing

TARMAC Aerosave and AerFin to Dismantle 10 A320neo and 737 MAX

TARMAC Aerosave and AerFin will teardown 10+ A320neo and 737 MAX aircraft by end of 2026 amid global parts shortages.

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TARMAC Aerosave and aviation asset management specialist AerFin will dismantle more than 10 new-generation narrow-body aircraft, including the Airbus A320neo and Boeing 737 MAX, before the end of 2026. The move highlights a growing industry trend where young airframes are scrapped to harvest high-value components amid ongoing global supply chain constraints.

In a press release issued on September 11, 2026, TARMAC Aerosave announced the strengthening of its 10-year partnership with AerFin to meet unprecedented aftermarket demand. To process the aircraft, TARMAC Aerosave has established a dedicated operational line tailored to AerFin’s specific teardown requirements.

Dedicated teardown operations

The new operational structure focuses on specialized extraction needs to accelerate the return of serviceable material to the market. TARMAC Aerosave has assigned a dedicated team to handle cabin removal, landing gear extraction, and the management of priority and standard parts lists.

“With more than 10 aircraft projects again this year for AerFin, this collaboration confirms our position as a leading player in the dismantling and recycling market,” stated Christian Ceruti, Chief Commercial Officer of TARMAC Aerosave. “Our dedicated organisation allows us to respond with the responsiveness that this high-demand market requires today.”

AerFin Chief Operating Officer Simon Bayliss noted that the program reflects the value the partnership creates for customers as the demand for new-generation aircraft material continues to grow. The companies confirmed that additional joint dismantling projects are already in preparation for 2027.

The economics of scrapping young aircraft

The aviation industry is currently experiencing a severe shortage of spare parts and engines, driven by manufacturing delays and maintenance backlogs. Engine durability issues, particularly with powerplants like the Pratt & Whitney Geared Turbofan (GTF), have left many operators searching for replacement components to keep their fleets active.

According to reporting by AeroCorner, this environment has led to young aircraft being scrapped for parts. In 2026, two Airbus A320neo aircraft previously operated by Spirit Airlines were recycled at just three and four years of age. The components and engines of these young jets proved more valuable on the secondary market than the intact airframes.

AirPro News analysis

We are witnessing a structural shift in aircraft lifecycle management. Historically, commercial airframes operated for 20 to 25 years before facing the recycler’s torch. The current supply chain environment has inverted this economic model for certain fleets. When a three-year-old Airbus A320neo is worth more as a collection of spare parts than as a flying asset, it underscores the severity of the engine maintenance backlog and the premium operators place on immediate parts availability. This collaboration between TARMAC Aerosave and AerFin is a direct market response to these constraints, and we expect similar teardown programs to accelerate through 2027 as long as original equipment manufacturer (OEMs) bottlenecks persist.

Sources: TARMAC Aerosave and AerFin, AeroCorner, Aviation Week

Photo Credit: TARMAC Aerosave

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MRO & Manufacturing

GKN Aerospace Breaks Ground on $16M New Hampshire Expansion

GKN Aerospace expands its North Charlestown, NH facility by 57,000 sq ft to boost aero-engine component production capacity.

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On September 10, 2026, GKN Aerospace broke ground on a $16 million expansion of its manufacturing facility in North Charlestown, New Hampshire, a move designed to increase production capacity for critical aero-engine components.

According to a press release issued by the company, the project will add 57,000 square feet to the existing site, bringing the total footprint to 97,000 square feet. The expansion aims to meet rising customer demand by bringing additional manufacturing processes in-house, thereby reducing supply-chain lead times and improving overall efficiency.

Expanding in-house manufacturing capabilities

The North Charlestown expansion will introduce new on-site manufacturing processes, specifically turning operations, surface finishing, and Non-Destructive Testing (NDT). By integrating these capabilities directly into the facility, GKN Aerospace intends to streamline its production pipeline for engine customers.

Tomas Lindsta, Senior Vice President of OE Product Solutions at GKN Aerospace, highlighted the operational benefits of the project.

“This expansion gives us the space to grow our team, increase production capacity and broaden our capabilities. By bringing more manufacturing processes in-house, we can further develop our employees’ skills, gain greater flexibility and respond more effectively to our customers’ evolving needs as our business continues to grow.”

Strategic investment and regional impact

The groundbreaking marks the execution phase of an investment strategy initially announced in early 2026. The $16 million commitment reflects a broader industry trend of aerospace suppliers consolidating critical manufacturing steps to mitigate supply chain vulnerabilities.

Joakim Andersson, President of Engines at GKN Aerospace, described the event as an important milestone for the company’s operations in the United States, noting that the investment will help grow capacity as demand from engine customers continues to rise.

New Hampshire Governor Kelly Ayotte also commented on the development, emphasizing the state’s role in the aerospace and defense sector.

“New Hampshire is proud to be a leader in the aerospace and defense industry, and GKN Aerospace’s expansion here is a testament to what is possible when industry investment and workforce development come together,” Ayotte said.

AirPro News analysis

The decision by GKN Aerospace to bring turning operations, surface finishing, and NDT in-house at the North Charlestown facility aligns with a growing emphasis on vertical integration among Tier 1 aerospace suppliers. As the commercial aviation sector continues to face constrained supply chains, reducing reliance on external vendors for specialized finishing and testing processes offers a distinct competitive advantage. We view this $16 million investment as a targeted effort to insulate the company’s aero-engine component production from external bottlenecks while simultaneously positioning the New Hampshire site for long-term workforce expansion.

Sources: GKN Aerospace

Photo Credit: GKN Aerospace

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