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Korin Iron Works, based in Japan’s Hokuriku region, specializes in manufacturing high-quality parts on state-of-the-art machining centers, including turbine blades for the aerospace industry and power generation facilities. In response to increasing market competition and rising customer quality demands, Korin considered a fundamental overhaul of its production processes.
In particular, there was an urgent need to improve various stages of the production process, including stabilizing processing quality, preventing unexpected quality issues, significantly reducing tool setup time, and alleviating the workload on operating personnel. To comprehensively address these challenges, Korin decided to implement the ZOLLER »venturion«, the premium system for professional tool setting and measurement.
With the introduction of the »venturion« adjustment device, processing accuracy improved significantly, 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 disposal costs for defective products. Specifically, cost reductions averaging over 20,000 euros per month were achieved and sustained over a period of about one year. This result directly contributes to improved production efficiency and cost reduction, which significantly increases customer satisfaction and substantially strengthens Korin’s competitiveness in the market.
Even in an environment with unavoidable temperature fluctuations within the factory», venturion« enabled measurements with extremely low deviations of 5 micrometers in the axial direction. This high-precision measurement made it possible to achieve a level of precision in single-pass machining that had previously been difficult to attain. This has opened up the prospect of significantly shortening the finishing process previously required, leading overall to shorter machining times and less material waste.
The change in tool measurement time following the introduction of ZOLLER’s premium presetting device», venturion«, is remarkable. Currently, approximately 150 tools are measured each month, and tool setup time has been reduced by about 70% compared to the period before the introduction. Furthermore, there is great confidence that the current working time can be nearly halved in the coming fiscal year as user proficiency increases. This significant time savings directly contributes to the efficiency of the production line and clearly demonstrates the high efficiency and positive return on investment of ZOLLER’s »venturion«.
Even one year after implementation, the ZOLLER »venturion« continues to help master the daily challenges of production operations and remains a reliable partner for Korin. Furthermore, based on this successful experience, Korin is now taking on the challenge of an even more advanced manufacturing technology aimed at the complete machining of precision parts in a single pass. For Korin, the introduction of the ZOLLER »venturion« is more than just an investment in equipment; it represents an innovation in their manufacturing process and an investment in the future.
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