Specific problem
The customer had to solve a specific problem. The grinding wheel would not make contact with the workpiece during the initial tool grinding program, requiring four to five adjustments before contact was established. Each adjustment took approximately 15 minutes, resulting in a total setup time of 1.5 hours per tool change.
Counteract Time Loss
This high expenditure of time is obviously accompanied by higher costs: With an average time charge of 100 Euro per hour, this translated to a substantial cost burden as we are talking about 150 tool changes per month by 10 tool grinding machines.
ZOLLER Solutions
To address these challenges, ZOLLER’s »genius« precision tool measuring device was introduced. The »genius« was utilized to precisely measure not only cutting tools but also the grinding wheels used in the tool grinding machine, implementing an external setup process.
Remarkable Improvements
The implementation of ZOLLER’s »genius« yielded overall benefits for the customer. First, grinding wheel air cuts could be eliminated by precise measurement of the grinding wheel shapes and dimensions. For sure, this meant a significant reduction in setup time: The elimination of air cuts resulted in a 1-hour reduction in setup time per tool change. Which means in total: the current setup time is 0.5 hours, meanwhile previously it was about 1.5 hours. In fact, enormous cost reductions can be recorded. The solution with ZOLLER translated to a monthly cost saving of approximately 15,000 euro based on time charge calculations.
Conclusion:
Cost Efficiency with ZOLLER »genius«
The introduction of the »genius« precision tool measuring device has significantly contributed to reducing setup time and costs in precision tool manufacturing at our customer. The high-precision measurement capabilities of ZOLLER’s »genius« eliminated grinding wheel air cuts, leading to increased efficiency in the manufacturing process. As future outlook, the company plans to continue utilizing »genius« measuring technology of ZOLLER to further enhance productivity and ensure consistent quality in their manufacturing processes.
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