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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.
The workshop has three 5-axis machining centers: two from DMG MORI and one from Hermle, each of which contributes to increasing operating time by around 20 minutes per day. With the introduction of »venturion«, it is now possible to use the 5-axis machines for an additional 240 hours per year.
The tool measurement data is transferred by »venturion« to each machine. The ZOLLER adjustment bench was also a decisive factor in the implementation of this system, as it can transmit data to control units from different manufacturers, including Siemens and Heidenhain. The data transfer function of »venturion« allows data to be changed immediately as soon as the tool is mounted, which also contributes to increased machine utilization.
(The results at the top of the page were obtained a few months after the installation of the ZOLLER »venturion,« and a further increase in utilization rates is expected.)
Thanks in particular to the advanced function Creation of tool lists with program sheets », Ituwa Kogyo has been able to significantly reduce tool preparation time in diversified small batch production. In addition, the function « Transfer of measurement results to machining centers »has 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 operation/process was reduced to approximately 5 minutes, regardless of the operator's experience. The longest setup time for changing parts was previously 6 hours! With the introduction of the »venturion«, this time has been reduced to around 30 minutes. This is a considerable reduction in working time, mainly due to the more efficient configuration of several boring bars.
According to Mr. Nukiguchi, CEO of Ituwa Kogyo, the option offered by the ZOLLER »venturion« to virtually anyone, regardless of their level of training, to quickly and easily perform precise settings has enabled the company to achieve very high profitability, which plays a decisive role from a management perspective.
The reduction in setup time has contributed significantly to shorter production times, which ultimately translates into greater customer satisfaction.
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