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Ituwa Kogyo, based in Hiroshima City, Japan, introduced ZOLLER’s high-precision tool setting device, »venturion«, in July 2023, thereby significantly reducing working hours and optimizing setup time for tools in high-mix, low-volume production. This innovation has contributed significantly to optimizing the manufacturing process and increasing customer satisfaction.
According to Nukiguchi, CEO of Ituwa Kogyo, the fact that virtually anyone can make precise adjustments quickly and easily with the ZOLLER »venturion«, regardless of their level of training, has led to very high cost efficiency—which plays a decisive role from a management perspective.
The reduction in setup time has contributed significantly to shorter production lead times, which ultimately leads to higher customer satisfaction.
The workshop houses three 5-axis machining centers: two from DMG MORI and one from Hermle, each of which contributes to an increase in operating time of about 20 minutes per day. With the introduction of »venturion«, it has become possible to operate the 5-axis machines for an additional 240 hours per year.
The tool measurement data is transmitted by »venturion« to each machine. The ZOLLER setting device was also a decisive factor in the implementation of this system, as it can transmit data to control units from various manufacturers, including Siemens and Heidenhain. The data transmission function of »venturion« enables immediate machining as soon as the tool is mounted, which also contributes to higher machine utilization.
(The results mentioned above were achieved within a few months of installing the ZOLLER »venturion«, and a further increase in operating rates is expected.)
In particular, with the advanced “Tool list creation with setup sheet” function, Ituwa Kogyo was able to drastically reduce tool preparation time in diversified small-batch production. Furthermore, the “Data transfer of measurement results to machining centers” function successfully reduced setup times, which significantly increased machine utilization.
With the boring bar, setup 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 could be reduced to about 5 minutes, regardless of experience. The most time-consuming setup time for machining parts used to be 6 hours! With the introduction of the »venturion«, this time was reduced to about 30 minutes. This was a significant reduction in working time, mainly due to the more efficient setup of multiple boring bars.
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