{"id":18335,"date":"2026-04-02T05:50:01","date_gmt":"2026-04-02T03:50:01","guid":{"rendered":"https:\/\/bbr.news\/?p=18335"},"modified":"2026-04-02T05:50:01","modified_gmt":"2026-04-02T03:50:01","slug":"more-flexibility-production-output-and-combating-the-shortage-of-skilled-workers","status":"publish","type":"post","link":"https:\/\/bbr.news\/en\/more-flexibility-production-output-and-combating-the-shortage-of-skilled-workers","title":{"rendered":"More flexibility, production output and combating the shortage of skilled workers"},"content":{"rendered":"<div class=\"shariff shariff-align-flex-end shariff-widget-align-flex-end\" data-services=\"facebook\" data-url=\"https%3A%2F%2Fbbr.news%2Fen%2Fmore-flexibility-production-output-and-combating-the-shortage-of-skilled-workers\" data-timestamp=\"1775109001\" data-hidezero=\"1\" data-backendurl=\"https:\/\/bbr.news\/en\/wp-json\/shariff\/v1\/share_counts?\"><ul class=\"shariff-buttons theme-round orientation-horizontal buttonsize-small\"><li class=\"shariff-button twitter shariff-nocustomcolor\" style=\"background-color:#595959\"><a href=\"https:\/\/twitter.com\/share?url=https%3A%2F%2Fbbr.news%2Fen%2Fmore-flexibility-production-output-and-combating-the-shortage-of-skilled-workers&text=More%20flexibility%2C%20production%20output%20and%20combating%20the%20shortage%20of%20skilled%20workers\" title=\"Bei X teilen\" aria-label=\"Bei X teilen\" role=\"button\" rel=\"noopener nofollow\" class=\"shariff-link\" style=\"; 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background-color:#999; color:#fff\"><span class=\"shariff-icon\" style=\"\"><svg width=\"32px\" height=\"20px\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" viewBox=\"0 0 32 32\"><path fill=\"#999\" d=\"M32 12.7v14.2q0 1.2-0.8 2t-2 0.9h-26.3q-1.2 0-2-0.9t-0.8-2v-14.2q0.8 0.9 1.8 1.6 6.5 4.4 8.9 6.1 1 0.8 1.6 1.2t1.7 0.9 2 0.4h0.1q0.9 0 2-0.4t1.7-0.9 1.6-1.2q3-2.2 8.9-6.1 1-0.7 1.8-1.6zM32 7.4q0 1.4-0.9 2.7t-2.2 2.2q-6.7 4.7-8.4 5.8-0.2 0.1-0.7 0.5t-1 0.7-0.9 0.6-1.1 0.5-0.9 0.2h-0.1q-0.4 0-0.9-0.2t-1.1-0.5-0.9-0.6-1-0.7-0.7-0.5q-1.6-1.1-4.7-3.2t-3.6-2.6q-1.1-0.7-2.1-2t-1-2.5q0-1.4 0.7-2.3t2.1-0.9h26.3q1.2 0 2 0.8t0.9 2z\"\/><\/svg><\/span><\/a><\/li><li class=\"shariff-button printer shariff-nocustomcolor\" style=\"background-color:#a8a8a8\"><a href=\"javascript:window.print()\" title=\"drucken\" aria-label=\"drucken\" role=\"button\" rel=\"noopener nofollow\" class=\"shariff-link\" style=\"; background-color:#999; color:#fff\"><span class=\"shariff-icon\" style=\"\"><svg width=\"32px\" height=\"20px\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" viewBox=\"0 0 30 32\"><path fill=\"#999\" d=\"M6.8 27.4h16v-4.6h-16v4.6zM6.8 16h16v-6.8h-2.8q-0.7 0-1.2-0.5t-0.5-1.2v-2.8h-11.4v11.4zM27.4 17.2q0-0.5-0.3-0.8t-0.8-0.4-0.8 0.4-0.3 0.8 0.3 0.8 0.8 0.3 0.8-0.3 0.3-0.8zM29.7 17.2v7.4q0 0.2-0.2 0.4t-0.4 0.2h-4v2.8q0 0.7-0.5 1.2t-1.2 0.5h-17.2q-0.7 0-1.2-0.5t-0.5-1.2v-2.8h-4q-0.2 0-0.4-0.2t-0.2-0.4v-7.4q0-1.4 1-2.4t2.4-1h1.2v-9.7q0-0.7 0.5-1.2t1.2-0.5h12q0.7 0 1.6 0.4t1.3 0.8l2.7 2.7q0.5 0.5 0.9 1.4t0.4 1.6v4.6h1.1q1.4 0 2.4 1t1 2.4z\"\/><\/svg><\/span><\/a><\/li><\/ul><\/div><h3>Challenging times require new developments. The demands for greater flexibility, higher production output and a simultaneous reduction in the number of skilled workers are growing louder. Wafios will be addressing current topics at Tube 2026 and offering solutions through automation, flexible production from batch size 1 and a bending system for plastic tubes. An AI-supported expert system for active operator support will also be presented.   <\/h3>\n<p>Today more than ever, operators are favoring technical solutions that make everyday production easier and provide more flexibility. Tool changing systems have been established on the market for some time now. Not least for contract manufacturing or small batch sizes, fast and uncomplicated tool changes are an important factor for smooth production and economic efficiency. However, Wafios now also includes the change of the bending form and with the new solution, the change is carried out without tools using a plug-in system. Downtime due to time-consuming manual retooling is avoided and the tedious and sometimes laborious opening of screws is also a thing of the past. It is obvious that this reduces set-up times to a minimum. The tool is available for the tube bending machines in the RBV and Topbend series. Visitors to Tube will be able to try out the new feature directly on the Topbend 35.       <\/p>\n<h4>Flexible prototyping for plastic pipes<\/h4>\n<p>From short set-up times to high adaptability in the plastics sector: The Hotbend 35 is a machine for a wide range of geometries and uses flexible CNC technology for bending plastic pipes. Faultless implementation requires a coordinated sequence between heating, bending, supporting and cooling. The Hotbend 35 therefore does not heat the entire pipe, but only the sections in which the bending takes place. A specially developed heating device is used for this, which can process various materials up to PA 12. At the same time, the pipe length to be heated can be adjusted to take account of special features of the material or geometry. In addition, the area that loses stiffness can be carefully and precisely optimized. The handling itself is carried out by a fully integrated robot. During the bending process, an inner mandrel supports the plastic tube from the inside, preventing the material from collapsing. Bending with an internal mandrel enables thin wall thicknesses and small bending radii with a homogeneous cross-section and smooth inner pipe surfaces for low pressure losses of the media flowing through. This means that the bend radius can be just as small as the outer diameter of the pipe if required. In addition to the flexible machine, series cells are also available for the production of plastic pipes in large batch sizes.          <\/p>\n<figure id=\"attachment_18333\" aria-describedby=\"caption-attachment-18333\" style=\"width: 250px\" class=\"wp-caption alignright\"><img fetchpriority=\"high\" decoding=\"async\" class=\" wp-image-18328\" src=\"https:\/\/bbr.news\/wp-content\/uploads\/2026\/03\/Abb1_Wafios_Twister35R_0088_HQ_klein-254x381.jpg\" alt=\"With the Twister\u00b2 35 RL, Wafios presents concepts for producing different tube geometries without retooling - even for production from a quantity of 1. \u00a9 Wafios\" width=\"250\" height=\"375\" srcset=\"https:\/\/bbr.news\/wp-content\/uploads\/2026\/03\/Abb1_Wafios_Twister35R_0088_HQ_klein-254x381.jpg 254w, https:\/\/bbr.news\/wp-content\/uploads\/2026\/03\/Abb1_Wafios_Twister35R_0088_HQ_klein-292x438.jpg 292w, https:\/\/bbr.news\/wp-content\/uploads\/2026\/03\/Abb1_Wafios_Twister35R_0088_HQ_klein-768x1152.jpg 768w, https:\/\/bbr.news\/wp-content\/uploads\/2026\/03\/Abb1_Wafios_Twister35R_0088_HQ_klein-1024x1536.jpg 1024w, https:\/\/bbr.news\/wp-content\/uploads\/2026\/03\/Abb1_Wafios_Twister35R_0088_HQ_klein.jpg 1333w\" sizes=\"(max-width: 250px) 100vw, 250px\" \/><figcaption id=\"caption-attachment-18333\" class=\"wp-caption-text\">With the Twister\u00b2 35 RL, Wafios presents concepts for producing different tube geometries without retooling &#8211; even for production from a quantity of 1. .<br \/>\u00a9 Wafios<\/figcaption><\/figure>\n<h4>Tube Automation &#8211; individual automation solutions<\/h4>\n<p>In addition to simplifications through tool solutions, the system manufacturer also has new developments to present in the field of automation. Wafios Tube Automation (WTA) is presenting a compact punching and stamping system with an integrated handling robot for the production of formed tube parts for garden tools. The robot takes over the complete part handling between the individual units and thus ensures an automated and reliable production process. Technically, the system is characterized by a high degree of flexibility: It enables the processing of different materials as well as the implementation of variable punching and embossing geometries. The solution illustrates how WTA can implement individual automation concepts in various expansion stages.    <\/p>\n<h4>Fast production from quantity 1<\/h4>\n<p>The Twister\u00b2 35 demonstrates an automated solution for production from the very first component. The tube bending machine with integrated robot shows a solution for automated bending of different tube dimensions without having to retool the machine. This means that a wide variety of tube geometries can be produced in any order, even in &#8220;batch size 1&#8221;, as is required in the hydraulics industry, for example. In the magazine, the different pipes are recognized by camera and the appropriate bending program is automatically selected. The bending tool is designed in such a way that different pipe diameters can also be processed without changing the tool. The Twister\u00b2 offers manufacturers clear advantages: The machine makes it possible to flexibly adapt the bending sequence and not be tied to a rigid sequence. This means that even extremely complex, three-dimensional component geometries can be realized precisely. In addition, bending across the middle allows the production of tube geometries with very short initial lengths on both sides &#8211; even in combination with large bending angles. These parts can be produced with a finished drop without the need for subsequent cutting.       <\/p>\n<h4>Easy set-up of components<\/h4>\n<p>The precise adjustment of a machine often requires sensitivity and experience. Day after day, qualified specialists use their knowledge to help keep production processes stable and efficient. However, identifying problems takes time, as does setting up the machines correctly &#8211; an effort that becomes a challenge in times of increasing shortage of skilled workers. This is where modern systems such as the Wafios Assistant and Mywafios.ai offer their help.   <\/p>\n<p>The new digital assistant from Wafios helps operators to set up the machines with instructions, images and videos. This also makes it much easier to set up complex parts. In addition to the setup sequences provided, operators have the option of creating their own individual assistance sequences to support the uniform setup of machines within the company. In-house know-how can thus be easily multiplied with the Wafios Assistant without leaving the company. The assistant actively supports the setter during programming, guides them intuitively through the entire operating system and automatically generates suitable machine programs based on templates. Wafios sees the new digital assistant as a significant step forward in the programming of complex machines.     <\/p>\n<h4>Don&#8217;t talk about AI &#8211; use it instead<\/h4>\n<p>The new AI function Mywafios.ai will also celebrate its world premiere at Wire &amp; Tube 2026. Wafios has been developing intelligent systems for providing information from documents for around four years. Mywafios.ai was developed on this basis. The AI helps operators with machine knowledge and supports them with questions about problems such as set-up, troubleshooting and tool replacement. The AI works on any mobile device, while the hosting runs on secure German servers. The machine itself, with its sensitive production data, does not require an internet connection.     <\/p>\n<p>The AI receives information from manuals, tutorials and machine plans as well as from experienced Wafios operators and service staff. Frequently occurring problems and their solutions are also stored. This ensures that answers are only drawn from trustworthy sources. A patent-pending communication system transmits the data securely via an optical QR code with an offline link. Cyber attacks on the machine are therefore not possible. A major advantage is that Mywafios.ai can respond in different languages. This makes it a practical international helper that is immediately available.      <\/p>\n<p>Wafios tube stand at Tube 2026: Hall 5, Stand A21<br \/>\n<a href=\"http:\/\/www.wafios.de\" target=\"_blank\" rel=\"noopener\">www.wafios.de<\/a><\/p>\n","protected":false},"excerpt":{"rendered":"<div class=\"mh-excerpt\">Challenging times require new developments. The demands for greater flexibility, higher production output and a simultaneous reduction in the number of skilled workers are growing louder. Wafios will be addressing <a class=\"mh-excerpt-more\" href=\"https:\/\/bbr.news\/en\/more-flexibility-production-output-and-combating-the-shortage-of-skilled-workers\" title=\"More flexibility, production output and combating the shortage of skilled workers\">[&#8230;]<\/a><\/div>\n","protected":false},"author":9,"featured_media":18334,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[616],"tags":[1746],"class_list":{"0":"post-18335","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-tube-wire","8":"tag-wafios-en"},"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v25.6 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>More flexibility, production output and combating the shortage of skilled workers - bbr B\u00e4nder Bleche Rohre<\/title>\n<meta name=\"description\" content=\"Challenging times require new developments. 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