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Ituwa Kogyo, based in Hiroshima City, Japan, introduced the high-precision tool presetter »venturion« from ZOLLER in July 2023 and was thus able to significantly reduce working hours and optimize the set-up time for tools in high-mix low-volume production. This innovation has made a significant contribution to optimizing the production process and increasing customer satisfaction.
Especially with the advanced function "Creation of tool lists with setup sheet", Ituwa Kogyo was able to drastically reduce the preparation time for tools in diversified small batch production. In addition, the "data transfer of measurement results to processing machines" function has successfully reduced set-up times, which has significantly increased machine utilization.
With the boring bar, the set-up time was reduced to 10 minutes for an experienced operator and 30 minutes for an inexperienced operator. With the »venturion« from ZOLLER, the entire process was reduced to around 5 minutes, regardless of experience. The most time-consuming set-up time for machining parts used to be 6 hours! With the introduction of the »venturion«, this time was reduced to around 30 minutes. This was a significant reduction in working time, mainly due to the more efficient setup of multiple boring bars.
There are three 5-axis machining centers in the workshop: two from DMG MORI and one from Hermle, each of which contributes to an increase in operating time of around 20 minutes per day. The introduction of »venturion« has made it possible to operate the 5-axis machines for an additional 240 hours per year.
The tool measurement data is transferred from »venturion« to each machine. ZOLLER's presetter was also a key factor in the implementation of this system, as it can transfer data to control units from various manufacturers, including Siemens and Heidenhain. The data transfer function of »venturion« enables immediate machining as soon as the tool is mounted, which also contributes to higher machine utilization.
(The above results were achieved within a few months of installing the ZOLLER »venturion« and further increases in operating rates are expected).
According to Nukiguchi, CEO of Ituwa Kogyo, the ability of the ZOLLER »venturion« to allow virtually anyone to make precise adjustments quickly and easily, regardless of their level of training, has led to very high cost efficiency - which is crucial from a management perspective.
The reduction in set-up time has contributed significantly to shorter production lead times, which ultimately leads to higher customer satisfaction.
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