Challenge Accepted

Previously, discrepancies in tool dimensions had a significant negative effect on the company’s production efficiency and quality. For example, they thought they had purchased a 12.03-mm drill, but the tool that was delivered had a diameter of 12.05 mm. This meant they did not have enough leeway for finishing and ultimately could not use that drill. With the introduction of »smile«, Five Straight was able to detect these dimensional errors in advance and set up the tools precisely. The ability for users to inspect and evaluate tools has proven to be a major advantage.

Improved Efficiency 

Drill rods: Compared to conventional tool setup procedures, the time required for this process has been significantly reduced, resulting in fewer production interruptions. For example, with drills, the condition of the cutting edge (wear status, etc.) can now be exactly inspected, allowing target and actual data to be entered. The average tool lifetime has increased from 100 drill holes/inserts to 150 to 200 drill holes/inserts, which corresponds to a lifetime that is more than 1.5 times the previous lifetime. This has not only led to a reduction in tool costs but also to an increase in efficiency, as fewer inserts need to be exchanged. 

The test grinding process for the drilling operation was very inefficient and took up a large portion of working time. With the default settings, the time-consuming lubrication of the drill head is almost completely eliminated, as the adjustment range is minimized. If the drill head is not lubricated, its lifetime is shortened. Another major advantage is that only a minimal number of drill rods need to be stored, since settings can now be made simple and precise. Previously, this company had to purchase a drill rod for every size, even if the diameters were only slightly different.

Complex Tools 

»smile« can be applied to complex tool configurations, particularly when setting up multi-edge tools. This has reduced the number of instances where rework was required due to setup errors and increased overall productivity.

A Complete Success 

Before the introduction of ZOLLER »smile«, no tool setting device was used, which meant that the machine would experience significant amounts of downtime if necessary, resulting in a significant waste of resources. Now, machine utilization has increased significantly. The high accuracy of the tool setting device has also significantly improved the efficiency of the CNC machine. We have seen direct increases in productivity, improvements in quality assurance, and cost reductions thanks to exact tool settings, as well as a reduction in the burden caused by inefficiencies and non-conforming parts. ZOLLER thus has a direct impact on productivity at Five Straight.