Achieving Streamlined Production and Less Downtime in Mold Making

Precision is paramount in manufacturing. Parts and protypes must be built without the slightest variations to achieve consistent performance — especially in high-stakes industries like aerospace, medical, and automotive. Accurate tool measurement is the critical first step in achieving first-class results.

Before learning about ZOLLER, Quest Industries had its CNC machine working double duty to measure tools and cut parts, which came at a cost. “If the machine’s measuring, then it’s not cutting,” said Tyler Boose, CNC Programmer at Quest Industries. “We don’t get paid to measure tools.” A ZOLLER »venturion« now measures and collects the tool data offline, allowing the CNC machine and its operator to focus on production. “All the operator has to do is put a tool in and enter an offset for that tool instead of using the CNC machine to measure,” said Boose. “It’s basically plug and play.”
 

Accurate and Consistent Tool Measurements 

Replacing manual tool measurement did more than save time — it also eliminated the risk of manual error. Not every machine at Quest Industries has a tool presetter, so the work was sometimes done by hand. “We would have tolerance discrepancies with how every operator would bring a tool down and touch it off,” said Boose. “Might be a thou here, thou there per part.” Now with the »venturion«, Quest Industries can get precise tool measurement data for its tools, regardless of operator. The machine’s high-quality industrial lens captures comprehensive tool geometry data faster and more accurately than a human can. “Having the consistency of a presetter definitely has benefits over an operator setting the tool by hand,” added Boose.

Getting these precise measurements is critical in production injection molding and mold building. Operators have one piece of material and even the smallest deviations scraps the part. It can cost companies like Quest Industries hundreds or thousands of dollars in scrap with each part run. “The job I was machining right before I saw ZOLLER…I scrapped a piece out. It was a $6,500 piece of material, stainless 15-5. I had a brand-new cutter on it that I never used before. We put it in the machine. I expected it to cut at 2.5 inches, and for whatever reason, it cut at 2.5 and 5 thou, and it scrapped the part. And of course, it was the last operation on the part,” said Boose. "So as soon as I saw, oh, I can confirm my tool measurement is exactly what it’s supposed to be [with ZOLLER], I knew instantly this is something we had to have.”

After introducing the »venturion« to the shop floor, Boose realized that having prestaged jobs waiting would require at least double the number of tool holders and a place to store them safely. ZOLLER Regional Sales Manager John Traxler invited Boose and Quest Industries President Dennis Hoover to ZOLLER’s North American Headquarters in Ann Arbor, Michigan, to explore the comprehensive range of TMS Tool Management Solutions, which include smart tool storage solutions and a robust tool management software system that is easily scalable for shops of all sizes. The visit demonstrated how the complete range of ZOLLER Solutions work together. Boose was especially interested in the ZOLLER »keeper«, a robust tool storage solution with both physical storage and digital inventory management. “Seeing that, how the »keeper«…can communicate with the »venturion«, we knew that to keep track of our tooling and tool holders…it was a must to have that whole system,” said Boose. “Having the TMS [tool management software] kind of wrapped it all together.” 

Although the company has only had the »keeper« for a few months, Quest Industries has already seen how a powerful tool management system can save time on the shop floor. 

"Setups that would take a day sometimes are now getting turned around in half an hour to an hour...the operators do not have to look for tooling because everything's in the tool crib being managed with the TMS system," said Boose.

The »venturion« presetter and »keeper« tool storage system have made it possible for Quest Industries to stage jobs up to a week in advance and plan for any potential disruptions. 

“If…our tool crib attendant Samantha can’t find the tool, she can come to us programmers ahead of time and we can find a solution. Do we have to buy another tool? Is the tool going to be available in the next week to use off of a different job? Just knowing ahead of time is a big deal,” said Boose. “We can look at every job scheduled…If something needs to be built up in a day or within the next hour, all she has to do is look at that schedule and she can go from there.”

After investing in the »venturion«, Quest Industries needed a solution to protect its growing stock of tool holders from damage. John Traxler, Regional Sales Manager at ZOLLER Inc., invited the Quest Industries team to the ZOLLER Inc. Tech Center to see how the »venturion«, and »keeper« work together.