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Korin Iron Works, based in the Hokuriku region of Japan, specializes in manufacturing high-quality parts on state-of-the-art machining centers, including turbine blades for the aerospace industry and power generation plants. In response to increasing competition in the market and the rising quality demands of customers, Korin considered a fundamental reform of its production processes.
In particular, it was necessary to improve several stages of the production process, including stabilizing processing quality, avoiding unexpected quality issues, significantly reducing tool preparation time, and reducing the workload of operating personnel. To address these challenges comprehensively, Korin decided to introduce the ZOLLER »venturion«, the premium system for professional tool setting and measurement.
With the introduction of the »Venturion« adjustment device, processing precision improved considerably, reducing the number of defective products from several per month to zero. This improvement not only reduced the number of defective parts, but also led to a reduction in various hidden costs, including additional material costs for rework, overtime pay for workers, and the costs of disposing of defective products. Specifically, cost reductions of more than €20,000 per month on average were achieved and maintained over a period of approximately one year. This result directly contributes to improving production efficiency and reducing costs, which significantly increases customer satisfaction and significantly strengthens Korin's competitiveness in the market.
Even in an environment with inevitable temperature fluctuations within the factory», venturion« enabled measurements to be taken with extremely low deviations of 5 micrometers in the axial direction. This high-precision measurement made it possible to achieve a level of accuracy that was previously difficult to achieve in single-pass machining. This has opened up the possibility of significantly shortening the finishing process that was previously necessary, resulting in shorter machining times and less material waste.
The change in tool measurement time following the introduction of ZOLLER's premium »venturion« presetting device is remarkable. Currently, around 150 tools are measured per month and tool preparation time has been reduced by approximately 70% compared to the time before the introduction. In addition, there is great confidence that the current working time can be reduced by almost half in the next fiscal year, thanks to increased user competence. This considerable time saving contributes directly to the efficiency of the production line and clearly demonstrates the high efficiency and positive effect of the investment in ZOLLER's »venturion«.
One year after its implementation, ZOLLER »venturion« continues to help overcome daily production challenges and is a reliable partner for Korin. Furthermore, based on this successful experience, Korin is now facing the challenge of even more advanced manufacturing technology, with the goal of complete machining of precision parts in a single pass. For Korin, the introduction of ZOLLER »venturion« is more than just an investment in equipment; it represents an innovation in its manufacturing process and an investment in the future.
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