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Ituwa Kogyo, headquartered 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 production process and has increased customer satisfaction.
In particular, thanks to the advanced “Tool List Creation with Setup Sheet” function, Ituwa Kogyo was able to drastically reduce tool setup time in its diversified small-batch production. In addition, the “Data Transfer of Measurement Results to Machine Tools” function successfully reduced setup times, which has 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 ZOLLER »venturion«, the entire process was 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 represented a significant reduction in working time, mainly due to the more efficient setup of multiple boring bars.
The shop floor is equipped with 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 transferred by »venturion« to each machine. The ZOLLER presetting machine was also a decisive factor in the implementation of this system, as it can transfer data to control units from various manufacturers, including Siemens and Heidenhain. »venturion«’s« data transfer function enables immediate machining as soon as the tool is fitted, 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.)
According to Nukiguchi, CEO of Ituwa Kogyo, the option that the ZOLLER »venturion« allows virtually anyone—regardless of their level of training—to make precise settings quickly and simply has led to very high cost efficiency—a factor that 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.
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