In small-part machining on Swiss-type lathes, challenges such as downtime from tool changes and setup adjustments, reliance on skilled operators, and dimensional variation have become major obstacles to improving productivity. Tungaloy’s modular head-change tool, “ModuMini-Turn,” structurally eliminates hidden losses—such as complex tool replacements, positional misalignments, and unexpected stoppages during unattended or nighttime operations—making it a highly regarded solution. In this article, we introduce the key features and implementation benefits, together with Mr. Sato of Tungaloy-NTK Vietnam LLC (hereafter Tungaloy Vietnam).

Cutting Tool Manufacturer Tungaloy: Over 90 Years of Expertise and Global Reach

Tungaloy is a comprehensive cutting tool manufacturer that developed cemented carbide for the first time in Japan in 1929. Leveraging a wide range of tool materials—such as CBN, PCD, and CVD—along with advanced tool design technologies, the company supports manufacturing operations worldwide. In Vietnam, Tungaloy operated as a representative office for approximately 10 years. In August 2024, it established Tungaloy-NTK Vietnam LLC, strengthening its local technical support system and accelerating proposal-driven activities for the Vietnamese manufacturing industry.

What Is the Modular Head-Change Tool “ModuMini-Turn”?

ModuMini-Turn is a high-rigidity, small-diameter modular head-change tool platform specifically designed for machining on Swiss-type lathes.

In conventional Swiss-type lathes, insert replacement must be performed within the machine’s confined internal space.
As a result, the following issues often occur:
▲ Increased operation time
▲ Tightening errors
▲ Insert misalignment

With ModuMini-Turn, the entire head unit—rather than just the insert—is replaced. By simply installing a pre-adjusted head outside the machine, the tool change is completed. This approach enables both a significant reduction in setup time and consistent machining accuracy.

Five Key Features That Enhance Swiss-Type Lathe Productivity

Tungaloy’s ModuMini-Turn not only streamlines tool changes but also helps improve overall shop-floor productivity. Its main features include:

① Significant Reduction in Setup Time
Replacing the entire head unit drastically shortens tool change time.
② Reduced Downtime
Machine stoppages are minimized, improving overall equipment utilization.
③ Improved Dimensional Accuracy
Pre-measurement outside the machine ensures consistent dimensional repeatability.
④ Standardized Operations
Even less-experienced operators can perform tool changes reliably.。
⑤ Rapid Recovery from Issues
Prepared spare head units allow immediate recovery in case of problems.

It is a tool platform designed to minimize dependence on skilled operators, enabling stable operation through a

system-based approach rather than relying on individual expertise

Implementation Case Studies in Japan and Thailand (Southeast Asia)

①Tool Change Time Reduced to One-Third (Kosmek – Thailand)

■ Challenge
Frequent dimensional deviations of 0.1 mm were observed during final inspection. These were caused by variability in in-machine insert replacement and inconsistent machining accuracy.

■ Results
• Tool change time was reduced from 30 minutes to 10 minutes.
• Daily downtime was cut by approximately 160 minutes, enabling production of up to 80 additional parts per day.
• Improved mounting accuracy in a well-lit workspace led to a roughly 30% reduction in defect rate.

"After six months of trial operation, the system was fully adopted. The modular head-change approach enabled both standardized operations and improved machine utilization, contributing to increased shop-floor productivity." — Mr. Sato, Tungaloy Vietnam

② External Setup for Swiss-Type Lathes (Suzuki Manufacturing Co., Ltd.)

■ Challenge
The confined space inside the machine made insert replacement and setup operations cumbersome. Dropped or lost parts and screws caused longer working times and increased costs.

■ Results
• Operation time was significantly reduced and standardized
(Skilled operator: 8 min → approx. 2.7 min / New operator: 19 min → approx. 3 min)
• Reduced downtime improved overall line utilization
• Risk of input errors and contact-related incidents was minimized, enabling stable operation

"By thoroughly performing pre-measurement and adjustments outside the machine and switching to the practice of installing pre-adjusted heads, we achieved zero trial cutting and zero machine stoppages, greatly enhancing equipment utilization." — Mr. Sato, Tungaloy Vietnam

Comprehensive Lineup for Swiss-Type Lathe Machining

The ModuMini-Turn series offers a versatile platform that accommodates a wide range of operations in Swiss-type lathe machining.

【Outer Diameter Machining】

【Grooving and Parting-Off】

▲ Outer-diameter grooving and parting-off head, compatible with high-pressure coolant (QC-JCTER/L-CHP)）

【Grooving and Threading】

▲ Screw-on type head for outer-diameter grooving and threading (QC-STCL)

【Shank】

▲ Shank for screw-on type heads, compatible with high-pressure coolant (QC-1012/1212/1616-CHP)

By using a common shank, multiple operations can be performed efficiently. In addition to standard products, the system also accommodates custom heads with special geometries, addressing the diverse requirements of small-part machining.

Simulation to Evaluate Cost-Effectiveness Before Implementation

We provide a simulation tool that enables users to estimate potential cost savings before implementation. By entering: • Tool change time • Number of holders • Number of tool changes • Production data the tool visualizes the system’s cost-effectiveness. ▶