Key to Efficiency
Especially with the one of »venturion«’s advanced features, i. e. “Tool list creation with setup sheet”, Ituwa Kogyo dramatically shortened the preparation time for tools in diversified, small-lot production by creating tool lists for each workpiece. In addition, the function “Data transfer of measurement results to machining equipment” successfully reduced setup times which has significantly increased machine utilization rates.
Significant Time Reduction
With the boring bar, setup time was reduced from 10 minutes for a skilled operator to 30 minutes for an inexperienced operator. ZOLLER’s »venturion« reduced the process to about 5 minutes, regardless of experience. The most time-consuming tool setup time for machining parts used to be 6 hours. With the introduction of »venturion«, this was reduced to about 30 minutes. This was a significant reduction in work time, mainly due to more efficient setup of multiple boring bars.
Considerable Cost Reduction
H7 tolerance boring allows one-shot (no-test cut) machining, eliminating the need for follow-up machining. The significant reduction in setup time has resulted in significant cost reductions. In addition, the 2-micron repeatability of the tooling allows for high-quality machining with all tools preset accurately in the ZOLLER »venturion«.
Increased Machine Utilization
There are three 5-axis machining centers on the shop floor: two from DMG MORI and one from Hermle, each contributing to an increase of about 20 minutes per day in operational time. With the introduction of »venturion«, it has become possible to operate the 5-axis machines for an additional 240 hours annually. Tool measurement data is transferred from »venturion« to each machine. The ZOLLER-made presetter was also a key factor in deciding to implement this system because it can transfer data to control units from various manufacturers, including Siemens and Heidenhain. The data transfer function of »venturion« allows for immediate machining once the tool is mounted, which also contributes to higher machine utilization rates. (The above results were achieved within a few months after the installation of ZOLLER’s »venturion«, and further increases in operational rates are expected.)
Improved Cost-Effectiveness
According to Ituwa Kogyo’s President Nukiguchi, the ability for anyone to quickly and easily perform precise setups has resulted in a very high cost-effectiveness – which for sure plays an important role from a management perspective.
Higher Customer Satisfaction
The reduction in setup times has significantly contributed to shortened manufacturingleadtimes,ultimatelyleadingtohigher customer satisfaction levels.
Ituwa Kogyo Conclusion: More Efficiency
The success story of Ituwa Kogyo exemplifies how the implementation of the »venturion« presetting machine from ZOLLER has facilitated efficiency and time savings in manufacturing processes. This technological innovation has played a pivotal role in improving product quality, reducing costs, and shortening delivery times, thereby optimizing operations and enhancing customer satisfaction.
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