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

The Boeing Company has selected Liebherr-Aerospace to supply the brake remote electronic unit for the in-development Boeing 777-8 Freighter. The Contracts, announced on July 31, 2026, expands the German manufacturer’s footprint of electronic components on Boeing Commercial-Aircraft.

The brake remote electronic unit (REU) functions as a data concentrator for the aircraft braking system. According to a press release issued by Liebherr, the system supports active brake monitoring and ensures compliance with Federal Aviation Administration (FAA) and European Union Aviation Safety Agency (EASA) Regulations regarding latent failure detection. Each Boeing 777-8 Freighter will be equipped with one brake REU.

Manufacturing and development footprint

The units will be developed and manufactured by Liebherr-Aerospace Lindenberg GmbH at its facility in Lindenberg, Germany. The company is executing the project in cooperation with CUONICS GmbH, an aviation electronics specialist based in Straubing, Germany.

Liebherr-Aerospace began development work on its remote electronic unit concept in 2018. The Boeing 777-8 Freighter contract marks the second type of REU the company will supply to Boeing. In January 2019, Boeing selected Liebherr to deliver the nose wheel steering REU for the Boeing 787 Dreamliner family.

Dr. Klaus Schneider, Chief Technology Officer at Liebherr-Aerospace & Transportation SAS, highlighted the long-term relationship between the two companies.

“We have worked in close collaboration with our customer over the past decade. To be on board Boeing commercial airplanes with our electronic products is an important milestone for Liebherr,” Schneider stated.

Expanding presence on Boeing platforms

Beyond the newly announced brake REU and the Boeing 787 nose wheel steering unit, Liebherr already supplies the main gear steering control unit for the current Boeing 777 program.

The Boeing 777-8 Freighter is the dedicated cargo variant of the Boeing 777X family. The aircraft is designed to replace older large-capacity freighters with improved fuel efficiency and lower operating costs.

AirPro News analysis

We view Liebherr’s expanding portfolio on Boeing aircraft as a clear indicator of the manufacturer’s successful transition from traditional hydro-mechanical systems to integrated electronic control architectures. Securing the brake REU contract for the Boeing 777-8 Freighter validates the strategic investment Liebherr made in 2018 when it launched its remote electronic unit concept. As aircraft systems become increasingly electrified and data-dependent, suppliers that can deliver compliant, localized data concentrators like the REU are well-positioned to capture market share on next-generation airframes.

Sources: Liebherr

The European Union Aviation Safety Agency (EASA) granted type certification to the Safran Arriel 2K turboshaft engine on July 8, 2026, clearing a critical regulatory hurdle for the Leonardo AW09 single-engine Helicopters program. Safran Helicopter Engines announced the certification milestone in a press release on July 30, 2026. The engine approval allows Leonardo to focus on the final aircraft certification and subsequent entry into commercial service for the AW09.

Testing and certification pathway

The Arriel 2K accumulated more than 4,100 hours of testing since its initial bench tests in 2022. This total includes over 600 flight hours. Safran conducted ground testing at its facility in Bordes, France, and at the French Defence Procurement Agency (DGA) testing center in Saclay, France. Flight testing took place in Mollis, Switzerland, utilizing the AW09 prototypes.

Safran Helicopter Engines CEO Cédric Goubet highlighted the program’s progression in the company’s July 30 statement.

“The certification of the Arriel 2K marks another defining step towards the entry into service of the AW09. All the teams at Safran Helicopter Engines are ready to support Leonardo and its customers in bringing this brand-new helicopter into service.”

Technical architecture and program integration

The Arriel 2K operates in the 1,000 shaft horsepower (shp) class. The engine architecture features a two-stage compressor utilizing one axial and one centrifugal stage, alongside an annular combustion chamber. The system is managed by a dual-channel Full Authority Digital Engine Control (FADEC) and includes an Engine Auxiliary Control Box (EACB) designed to reduce pilot workload during operation.

Leonardo selected the Arriel 2K for the AW09 program on January 26, 2023. This decision replaced the previously planned Honeywell HTS900 engine. The AW09 was originally developed by Kopter Group, which Leonardo acquired in April 2020. Following the engine selection, the Arriel 2K completed its Maiden-Flight on the AW09 PS4 prototype on March 16, 2023. Safran has produced more than 15,500 engines in the Arriel family to date.

AirPro News analysis

Leonardo took a calculated schedule risk when it opted to change the AW09 engine supplier in early 2023. Securing EASA type certification for the Arriel 2K just over three years after that decision validates the integration strategy. We view the selection of the Arriel family as a move to leverage an established global support network. With more than 15,500 Arriel engines already in the field, prospective AW09 operators will have access to a mature maintenance infrastructure upon the helicopter’s entry into service. The focus now shifts entirely to the AW09 airframe certification campaign.

Sources: Safran