Fast production, tight delivery schedules, and an increasing shortage of skilled workers present major challenges for modern manufacturing. Intelligent systems and innovative solutions help simplify the work of machine operators while enabling manufacturers to maintain productivity and efficiency.
The shortage of skilled labor continues to dominate headlines and in many manufacturing companies, it has already become a daily reality. Fewer qualified employees place greater demands on experienced operators, increasing the risk of errors and delayed deliveries. Intelligent assistance systems help mitigate these challenges by supporting existing employees while making it easier for new operators to get up to speed.
“The shortage of skilled workers is becoming increasingly noticeable. A small number of experienced operators are often responsible for keeping production running, while training new employees becomes more difficult. At the same time, valuable expertise is lost if it is not systematically passed on. That's why we need AI-powered systems that support machine operators and serve as a digital memory of our experienced operators,” says Dr. Uwe-Peter Weigmann, CEO and Spokesman of the Executive Board of WAFIOS. “With myWAFIOS.ai and the WAFIOS Assistant, we make the knowledge of our experienced employees available to everyone, anytime and directly at the machine. This shortens training times, reduces setup times, and ensures that answers to important questions are available exactly when they are needed,” adds Jörg Eisele, Member of the Executive Board responsible for Sales at WAFIOS.
Fast Answers with AI
When new employees join a company or young operators are learning to work with machines, experienced colleagues must spend valuable time training them. Intelligent assistance systems enable new employees to become productive more quickly and work independently sooner. Since 2020, WAFIOS has offered a powerful digital maintenance solution with its maintenance software connectavo. The cloud-based, mobile platform helps companies organize maintenance processes efficiently while providing fast and targeted access to information through its AI assistant, Conny. This proven technology now also forms the foundation of myWAFIOS.ai. The AI assistant supports operators with questions related to machine setup, troubleshooting, and tool changes. Whenever a question arises, users can access myWAFIOS.ai, which searches technical documentation, manuals, and validated knowledge provided by experienced WAFIOS specialists to deliver an immediate answer. The system can be accessed simply by scanning a QR code located on the machine, requiring only a smartphone. Communication is securely transmitted via an optical QR code with an offline link. The machine itself remains offline at all times, ensuring maximum protection against cyberattacks.
Even experienced operators benefit from myWAFIOS.ai by finding machine-related information faster and more efficiently. If the required information cannot be found, users are only one click away from contacting the WAFIOS Service team.
Simplifying Machine Setup and Preserving Knowledge
At wire & Tube 2024 in Düsseldorf, one of the world's leading trade fairs for the wire and tube industry, WAFIOS introduced machines equipped with assisted and automated functions. These innovations help manufacturers address the shortage of skilled workers, and WAFIOS continues to expand this approach in 2026. The WAFIOS Assistant is a unique system that supports machine operators during setup through two intelligently connected displays. While setting up new parts previously required extensive classroom training, operators can now complete setup procedures and training directly through the WAFIOS Assistant. Valuable expertise is digitally captured and made permanently available, making knowledge accessible regardless of individual experience. As a result, setup procedures become standardized, company knowledge is preserved, and valuable know-how is passed on to the next generation of operators. All data remains securely within the customer's own company.
Smart Support Starts at the Pay-Off
Operator assistance begins even before production starts, with the Smart Pay-Off Interface (SPI). SPI seamlessly connects the pay-off and the machine into one intelligent system. The connected machine automatically configures the pay-off unit, presetting the basic rotation speed and other relevant parameters based on available production data.
The interface also introduces a new level of transparency: all key information, including pay-off speed, force settings of the pay-off arm, and the current operating status, is displayed clearly at all times. The new generation of pay-offs equipped with SPI is available for various WAFIOS wire bending, straightening, and spring machines. For operators, this means automatic setup and a clear overview of all essential parameters directly on the machine display.
