Achieving significant time savings during tool measurement

One of our customers based in the Kansai region of Japan was experiencing significant time losses during the set-up process for precision tool production, particularly with small diameter tools of D 0.6 mm or less. For the customer, the main problem was frequent "air cuts" in the grinding wheel.

The problem

The grinding wheel did not make contact with the workpiece during the first tool grinding program, so four to five adjustments were required before contact could be made. Each adjustment took about 15 minutes, resulting in a total set-up time of 1.5 hours per tool change.
 

This high expenditure of time naturally went hand in hand with higher costs. At an average hourly rate of 100 euros per hour and about 150 tool changes per month on 10 tool grinding machines, there was a considerable cost burden.

The solution

The »genius« precision measuring machine from ZOLLER was introduced to precisely measure cutting tools, as well as the grinding wheels used in the tool grinding machine. 
 

The precise measurement of the grinding wheel shapes and dimensions eliminated air cuts in the grinding wheels, reducing set-up time considerably: from 1.5 hours to .5 hours, or one hour per tool change. This led to monthly cost savings of approx. 15,000 euros, based on corresponding projections.

The result: Cost efficiency with ZOLLER »genius« 

Introducing the »genius« universal measuring machine made a significant contribution to reducing set-up times and costs in precision tool production for our customer. The high-precision measuring functions of the ZOLLER »genius« have eliminated the air cuts of the grinding wheel, resulting in greater efficiency in the manufacturing process. 

Looking ahead, the company plans to continue using ZOLLER »genius« measurement technology to further increase productivity and ensure consistent quality.