More efficiency and higher quality with »smile«

ZOLLER is the ideal partner for tool setting

This is a detailed analysis of the introduction of the »smile« tool presetter from ZOLLER at Five Straight, a company based in Kanzakigun, Hyogo Prefecture, Japan. The company's goal is to efficiently produce high-precision parts in the manufacturing industry.

In order to carry out high-mix-medium-volume production (multiple industries, multiple materials) with a small number of employees, the company is constantly striving to streamline and optimize all processes. Specific challenges on the shop floor included dimensional errors and tool wear, as well as improper set-up procedures that directly led to poor quality and inefficiency. To solve these problems, Five Straight introduced the ZOLLER »smile« tool presetter.

Challenge accepted

Previously, discrepancies in tool dimensions had a significant negative impact on the company's production efficiency and quality. For example, a 12.03 mm drill bit was thought to have been purchased, but the tool that was actually delivered had a diameter of 12.05 mm. This meant that they did not have enough margin for finishing and, ultimately, could not use that drill bit. With the introduction of »smile,« Five Straight was able to detect these measurement errors in advance and configure the tools with precision. The ability for users to check and evaluate the tools has proven to be a great advantage.

Greater efficiency

Drill bars: Compared to conventional tool preparation processes, the time required for this process has been significantly reduced, resulting in fewer production interruptions. For example, in the case of drilling tools, the condition of the cutting edge (wear status, etc.) can now be checked accurately, allowing theoretical and actual data to be entered. The average service life of the tools has increased from 100 holes/inserts to between 150 and 200 holes/inserts, which corresponds to more than 1.5 times their service life. This has not only reduced tool costs, but also increased efficiency, as fewer inserts need to be changed.

The trial grinding process for drilling was very inefficient and consumed a large part of the working time. With the standard configuration, the laborious lubrication of the drill head is almost completely eliminated, as the adjustment range is minimized. If the drill head is not lubricated, its service life is shortened. Another major advantage is that only a minimum number of drill bars now need to be stored in the warehouse, as adjustments can be made easily and accurately. Previously, this company had to purchase a drill bar for each size, even though the diameters differed only minimally.

Complex tools

»smile« can be applied to complex tool configurations, especially in the configuration of multi-edged tools. This has reduced the number of cases where rework was necessary due to configuration errors and increased overall productivity.

Total success

Before introducing ZOLLER »smile«, the tool setting device was not used at all, which meant that the machine could remain idle for long periods of time, resulting in a considerable waste of resources. Now, machine utilization has increased significantly. The high precision of the tool setting device has also significantly improved the efficiency of the CNC machine. We have seen a direct increase in productivity, improvements in quality control, and a reduction in costs thanks to the exact adjustment of the tools, as well as a decrease in the burden caused by inefficiencies and non-conforming parts. Therefore, ZOLLER has a direct influence on the productivity of Five Straight.