Significant time savings in tool measurement

One of our customers, based in Japan’s Kansai region, experienced significant time losses during the setup process for precision tool manufacturing, particularly with small-diameter tools measuring D 0.6 mm or less. For the customer, the main problem was frequent “dry cuts” in the grinding wheel.

Specific Problem 

The customer therefore had a specific problem to solve. The grinding wheel did not come into contact with the workpiece during the first tool-grinding program, so four to five adjustments were required before contact could be established. Each adjustment took about 15 minutes, resulting in a total setup time of 1.5 hours per tool change.
 

Enormous Time Loss 

This significant time investment naturally comes with higher costs: At an average hourly rate of 100 euros per hour, this represents a substantial financial burden, given that we’re talking about 150 tool changes per month across 10 grinding machines.

ZOLLER Solutions 

To overcome these challenges, ZOLLER introduced the »genius« precision measuring machine. The »genius« was used to precisely measure not only cutting tools but also the grinding wheels used in the tool grinder, thereby implementing an external setup process.  

Many Improvements 

The introduction of the ZOLLER »genius« brought the customer remarkable benefits overall. First, the precise measurement of the grinding wheel shapes and dimensions eliminated air cuts on the grinding wheels. This resulted in a significant reduction in setup time: The elimination of air cuts led to a reduction in setup time of one hour per tool change. Overall, this means that the current setup time is 0.5 hours—compared to approximately 1.5 hours previously! In fact, this has resulted in enormous cost savings. The ZOLLER solution resulted in monthly cost savings of approximately 15,000 euros, based on projections that corresponded to the actual figures.

The introduction of the high-precision Universal measuring machine, »the »genius«, has significantly contributed to reducing setup times and costs in precision tool manufacturing at our customer’s facility in the Kansai region. The high-precision measuring functions of the ZOLLER »genius« have eliminated air cuts by the grinding wheel, resulting in greater efficiency in the production process. Looking ahead, the company plans to continue using ZOLLER’s »genius« measuring technology to further increase productivity and ensure consistent quality in its production processes.