100-year-old manufacturer embraces innovation with INH 63
KUSUDA Co., Ltd. was established more than 100 years ago in 1920. The company started as a casting provider, but entered the machining field in the 1980s for higher business value. Since then, Kusuda has achieved significant growth by developing a unique system to handle the whole process from casting to machining and direct product delivery by themselves.
Kusuda continues to uphold its philosophy of “Unity and Advance” to this day with its state-of-the-art technology, machine tool parts and castings that directly contribute to the development of the manufacturing industry. Kusuda has been a supplier for DMG MORI since the very beginning, providing various parts such a spindle housings and flanges. On the other hand, Kusuda has also been a user of DMG MORI machines since the 1980s, with approximately 40 machines currently in operation. In constant pursuit of innovation, Kusuda has used the 5-axis machining center DMU 50 and the NLX 2500 with the touch screen control panel and CELOS since the 2010s. Now, in 2023, they became pioneer users of the new 5-axis machining center INH 63.
Process integration for less setup changes Significantly higher productivity and operator safety
Kusuda handles all processes from casting to machining in their own high-mix, low-volume production system, with pieces up to 200 kg. Conventionally, these processes require time-consuming setups on 3-axis and 4-axis horizontal machining centers. But with the INH 63, processes can be integrated and the number of setup changes drastically reduced. Mr. Kiyoto Kusuda, manager of the sales department, adds: “With large or heavy pieces, setup changes can be dangerous. Consequently, process integration leads to less hazardous work and higher safety for our staff.” The INH 63 utilizes a powerful spindle with a standard maximum spindle torque of 808 Nm and a spindle output of 85 / 40 kW (10 % ED / cont.). This enables both heavy-duty and high-speed machining, thus boosting productivity with higher machining speed.
CPP pallet handling system for high-variety production with maximized machine utilization
Kusuda manufactures their in-house casting materials to be close to the final casting shape, which enables higher efficiency during the actual machining and shorter lead times compared to machining from block-shaped materials. To increase the machine utilization further, unmanned night shifts with a high number of pallets are necessary. Fur Kusuda, this meant to introduce the INH 63 with an 8-station CPP (Compact Pallet Pool) to their production.
„Actually, our factory floor space would have limited us to only 6 stations under the standard design, but thanks to DMG MORI‘s special design, we were able to install the larger 8-station CPP,“ Mr. Kusuda recalls. In addition, the technology cycle CELOS Chatter Control is employed to automatically optimize cutting conditions. „By avoiding chatter on the finished surface, we can reduce our workload and improve productivity. Moreover, the tool management system allows us to safely machine without overworking the tools, and even if a tool is damaged during night shift, the tool breakage detection prevents accidents“, says Mr. Kusuda, appreciating the productivity-enhancing features.
Strong against chips, coolant, and mist to improve the working environment
The INH 63 adapts the new zero-sludge COOLANT pro, an evolved version of the original zero sludge coolant tank with high-performance chip cleaning capabilities to prevent chips accumulation inside the machine and support long unmanned operation. Why is it crucial to reduce tank cleaning? Mr. Kusuda recalls past workloads and states that: “Sludge accumulates quickly in the coolant tank because we mainly machine FC casting. In the past, three workers spent a whole day cleaning the tank two to three times a year.”
The built-in mist collector zeroFOG collects more than 99.97 % of particles as fine as 0.3 µm in diameter, preventing problems caused by mist. Mr. Yamanaka smiles: „Thanks to zeroFOG, the machine is not filled with mist at all and the view is really clear. I can machine without worrying about cutting conditions, which improves production efficiency.“ To which Mr. Kusuda adds: „And a cleaner working environment means better operator health.“
Seeking growth and sustainable production with the latest technology
When President Yoshinori Kusuda first heard of the INH 63, the new machine immediately caught his attention. Originally, he had planned to replace the company’s existing 4-axis MH-63 with an NHX 6300 2nd Generation, another horizontal machining center capable of 4-axis machining, but suddenly changed his direction. What caused him to rethink the investment?
„The INH 63 perfectly embodies our corporate identity: to grow together with our customers through the latest technology, equipment, and services. We believe that the INH 63 and its concept of process integration for high-speed, high-precision machining will be a powerful asset to further promote our unique strength, that is the full in-house casting production from raw material to machined products. In addition, the INH‘s high energy-saving performance proved ideal in terms of both sustainable production and contribution to the realization of a carbon-neutral society.“ Another crucial factor was the attention to detail that went into the design of the INH 63. machining speed. The new INH 63 has not only boosted productivity but also sparked new motivation on the shop floor and improved the working atmosphere.
„The machine uses a double fixation for the table to achieve high rigidity, and this shows how much the machine has evolved in terms of its basic structure and chip disposal performance. Also, the INH is stylish to look at and greatly motivates our operators“, Mr. Kusuda concludes.
KUSUDA Co., Ltd.
Headquarters / Factory:
2140 Oudashimocha,
Uda-city, Nara 633-2170, Japan
http://kusuda.co.jp/index.html