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  KAIZEN point 1

  KAIZEN to replace into Magnetic type honing head.

  Previously, this customer was outsourcing the regluing and cylindrical grinding of replacement stones. We replaced their honing head with the magnetic type head so that operators can easily replace the stones themselves. With no more outsourcing and long delivery times, their production system became simple and smooth.

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  KAIZEN point 2

  KAIZEN to rethink the process.

  Previously, this customer was processing with 5 stones for roughing and 5 stones for finishing, using a total of 10 stones. We changed the process from having two parts into one process and reduced the number of stones from 10 to 8. Furthermore, we achieved a 20% cost reduction by changing the stone specifications.

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  KAIZEN point 3

  KAIZEN to process with low pressure.

  We changed the angle of the taper cone from 30 degrees into 35 degrees. By changing the angle, the pressure of the stone surface reduced and the accuracy was improved. Also the usable stone layer became larger, resulting in lower running costs.

KAIZEN proposal of INAKEN.
Running cost comparison with original tool.

With an over all improvement, a significant redution in cost was achieved.

• No need to reglue when using the Magnetic type honing head.
• A larger usable layer and processing with lower pressure doubled the stone life.
• 50% cost reduction after rethinking tools from the root.
• Improvement of accuracy and reduction of defect rate.