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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, there was an urgent need to improve various stages of the production process, including stabilizing processing quality, avoiding unexpected quality problems, significantly reducing tool setup time and reducing operator workload. 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 setting tool«, 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 the reduction of various hidden costs, including additional material costs for reworking, overtime payments for workers and disposal costs for defective products. Specifically, cost reductions averaging over €20,000 per month were achieved and maintained over a period of approximately one year. This result contributes directly to improving production efficiency and reducing costs, which significantly increases customer satisfaction and strengthens Korin's competitiveness in the market.
Even in an environment with unavoidable temperature fluctuations within the factory, »venturion« enabled measurements with extremely small deviations of 5 micrometers in the axial direction. This high-precision measurement has made it possible to achieve a level of precision in single-pass machining that was previously difficult to achieve. This has opened up the prospect of significantly shortening the previously required finishing process, resulting in shorter machining times and less material waste overall.
The change in tool measuring time following the introduction of ZOLLER's premium »venturion« presetter is remarkable. Currently, around 150 tools are measured each month and tool set-up time has been reduced by around 70% compared to before the introduction. Furthermore, there is great confidence that the current working time can be almost halved in the coming financial year as user competence increases. This considerable time saving contributes directly to the efficiency of the production line and clearly demonstrates the high efficiency and positive investment effect of the »venturion« from ZOLLER.
One year after implementation, ZOLLER »venturion« continues to help meet the daily challenges of production operations and is a reliable partner for Korin. Furthermore, based on this successful experience, Korin is now taking up the challenge of even more advanced manufacturing technology aimed at the complete machining of precision parts in a single pass. The introduction of the ZOLLER »venturion« is more than just an investment in equipment for Korin; it represents an innovation in their manufacturing process and an investment in the future.
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