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Agricultural machinery manufacturing places heavy demands on sheet metal production. Components must withstand harsh operating conditions, fit accurately into complex assemblies and be produced across changing batch sizes. For Australian manufacturers, these requirements are compounded by skilled labour shortages, rising costs and pressure to remain competitive while continuing to manufacture locally.
CLAAS faces many of the same production challenges at its Bad Saulgau facility in Germany, where it manufactures components for forage harvesters and their attachments. Batch sizes range from 50 to 200 parts, components vary considerably in size and complexity, and some require up to 13 bends. Tight tolerances must also be maintained for the robotic welding processes that follow. To improve flexibility and productivity, CLAAS introduced press brake automation in stages. A TruBend 5000 with automatic ToolMaster simplified tool setup, while a TruBend 7050 with a mobile Flex Cell added flexible automated production. Repeat components can now be processed automatically, including during unattended periods, while manual bending remains available for complex parts, prototypes and urgent work. By improving setup, planning, machine availability and production flow, CLAAS reduced its production requirement from three shifts to two. The CLAAS experience has clear relevance for agricultural machinery manufacturers across Australia and New Zealand. It shows how automation can address a specific production constraint while preserving the flexibility required for varied component work.
About CLAAS: Headquartered in Harsewinkel, Germany, CLAAS is a leading manufacturer of agricultural machinery. Its Bad Saulgau facility produces components and attachments for forage harvesters, creating a varied workload for the sheet metal team. Although this installation is located in Germany, its lessons are relevant to Australian and New Zealand businesses involved in sheet metal applications. It shows how automation can begin with a specific production constraint and expand as requirements change Read more about CLAAS
“Automation should not be an end in itself,” says Marco Schwab, Head of Sheet Metal Processing at the CLAAS Bad Saulgau facility.
CLAAS needed to produce a varied mix of agricultural machinery components in batches ranging from 50 to 200 parts. The bending department works with long, heavy tools and clamping lengths of up to three metres. Setting up this tooling manually several times during a shift placed considerable physical strain on employees. A specialised bending tool was also available on only one existing machine. This restricted where certain large components could be produced and created a bottleneck in production planning. Quality was equally important. Many of the bent parts proceed directly to robotic welding, requiring bending tolerances of approximately plus or minus 0.25 degrees. That tolerance has to remain consistent from the first component to the last, including during unattended night production. CLAAS therefore needed to improve tool availability, production capacity, ergonomics and process consistency while retaining the flexibility required for its varied component mix.
As part of a group-wide investment program focused on automation, CLAAS chose to introduce automated bending in stages. The company invested in two complementary TRUMPF bending solutions:
Each machine addressed a different production requirement. Together, they gave CLAAS a practical way to introduce automation without losing the flexibility needed for its varied component mix.
The TruBend 5000 replaced an older press brake and brought greater flexibility and better ergonomics to the bending department. CLAAS works with long, heavy tools and clamping lengths of up to three metres. Setting up this tooling manually several times during a shift placed considerable physical strain on employees. The automatic ToolMaster tool changer now handles these tool changes. It reduces the amount of repeated lifting and positioning required from operators while making machine setup more consistent. The investment also resolved an existing production bottleneck. A specialised bending tool had previously been available on only one machine. This restricted where certain large components could be produced and made production planning more difficult. CLAAS can now manufacture these large components in parallel on two machines. The additional capacity has given the production team greater certainty when planning workloads and delivery schedules.
The TruBend 7050 with Flex Cell marked the next stage in CLAAS’s move towards automated bending. Flex Cell is a mobile, retrofittable automation system that can be connected to or detached from the TruBend 7050 in a few simple steps. When Flex Cell is connected, the TruBend 7050 operates as an automated bending cell. When production requirements change, the automation can be removed and the machine returned to manual press brake operation. This allows CLAAS to automate larger production batches while retaining the option to process complex parts or smaller quantities manually. The ability to move between automated and manual production was a deciding factor for the business. During normal production, the TruBend 7050 is now used primarily in automated mode. It can continue producing parts unattended during off-peak periods and night shifts, extending productive machine hours. The press brake also remains available as additional capacity for complex components or urgent work. CLAAS can change the production mode according to the parts being processed and the capacity required at the time. For manufacturers across Australia and New Zealand, this type of flexible bending automation can provide a practical way to increase output while retaining the versatility needed for mixed production.
The investment in TRUMPF bending technology has delivered several operational improvements for CLAAS:
Quality remains the priority at CLAAS, regardless of whether a component is produced manually or automatically. Many of the bent parts proceed directly to robotic welding. As a result, CLAAS must maintain bending tolerances of approximately plus or minus 0.25 degrees. That tolerance has to remain consistent from the first component to the last, including during unattended night production. CLAAS has achieved reliable results with the automated system. Component quality remains consistent, processes run smoothly and rejects across larger production batches can be avoided. This stability gives the company the confidence to extend production beyond staffed shifts without compromising the quality required by downstream welding processes.
The TruBend 5000 allows large components to be manufactured in parallel across two machines, removing a previous tooling bottleneck and improving planning certainty. The TruBend 7050 with Flex Cell gives CLAAS the flexibility to automate repeat batches while retaining manual capability for complex parts, smaller quantities and urgent work. The system can also continue operating unattended during off-peak periods and night shifts.
Following the installation of the TruBend 5000, CLAAS reduced the required production schedule from three shifts to two. The TruBend 5000 is not faster than the press brake it replaced. The improvement comes from the productivity of the complete bending process. Automatic tool changes, improved machine availability, parallel production and better planning have allowed CLAAS to produce more efficiently across fewer shifts. This result highlights the importance of looking beyond the bending cycle when assessing a new press brake. Tool setup, programming, handling, machine availability and production flow all influence the final cost and output of a component.
CLAAS is a family-owned company and takes its responsibility towards employees seriously. This was an important consideration as automated processes were introduced. Some employees were initially cautious about the new technology. That hesitation eased quickly as they became familiar with the equipment and saw how their roles would develop. Operators now spend more time monitoring production, optimising processes and managing quality. Robot programming and digital process control have also become more prominent within the bending department. These technical responsibilities can be particularly appealing to younger employees entering manufacturing. CLAAS believes automation can enhance the status of the bending profession by combining practical production experience with programming, process control and quality management. The technology supports the expertise of the production team while reducing repetitive and physically demanding work. This is especially relevant in Australia and New Zealand, where experienced manufacturing employees remain difficult to recruit and retain. Automation can help businesses use existing skills more effectively while creating safer and more technically engaging roles. Appropriate machinery and operator training remains essential. Employees need a clear understanding of the machine, software and production process if the business is to achieve the full value of an automated system.
The developments at Bad Saulgau are the beginning of a wider automation journey for CLAAS. The company is already evaluating further projects, including opportunities within laser processing. Its approach remains practical. Automation is seen as an opportunity when it makes commercial sense, improves quality and supports employees. That thinking shaped the selection of the TruBend 5000 with ToolMaster and the TruBend 7050 with Flex Cell. The systems were chosen because they suited the components, batch sizes and working practices at the facility.
Agricultural machinery production can involve heavy-gauge materials, complex geometries, large and small components, changing batch sizes and demanding quality requirements. Accurate bending is also essential for efficient downstream welding and assembly. Before recommending a solution, Headland reviews the components being produced, material types, batch volumes, tooling requirements and current workflow. This helps identify where production time is being lost, which parts are suitable for automation and how the technology can improve the complete manufacturing process. As the official TRUMPF agent in Australia and New Zealand, Headland supports agricultural equipment manufacturers with machinery selection, application assessment, project coordination, installation, operator training and ongoing technical support. The right approach may combine automated bending for repeat components and unattended production with manual capability for prototypes, complex parts and urgent work. Depending on the application, the objective may be to increase capacity, reduce setup time, improve ergonomics, maintain consistent bending quality or support more efficient welding and assembly.
In regional Victoria, Gason has applied this thinking through an integrated manufacturing environment combining TRUMPF laser cutting and robotic bending, STOPA material storage and OSEON production software. The investment has strengthened Gason’s capacity to manufacture precision agricultural equipment locally and develop new products for the Australian farming sector.
Talk to Headland about your components, materials, batch sizes, current production constraints and future capacity requirements.
Whether you’re after a machine, spare part, power tool, or need to book a service call Headland will help you find the right solution in a timely manner.
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