Iowa Metal Spinners (IMS), a contract manufacturer of spun metal components used by assemblers and fabricators throughout the U.S., anticipates market trends, needs, and requirements, and counts on MJC Engineering and Technology to provide behind-the-scenes horsepower to drive its growth and expansion.
Homespun In the Heartland
Founded in 1980 by Kevin Harberts, IMS fabricates from cold rolled, aluminized, galvanized, aluminum, brass, and many more metals ranging in thickness from 0.010-0.250 in., depending on the alloy and configuration of the part. Each year the company processes over 1.5 million lb of aluminum for use in HVAC, fan housings, and products for the lighting industry.
In 2000, IMS moved into a high-tech facility located in a state-of-the-art industrial park in Cedar Falls. Brightly lighted and clean, the manufacturing plant embodies the best elements of today's most advanced industrial facilities, and was designed to provide a workflow that would allow IMS to move product more quickly and with more efficiency than most companies of similar size and range of product capabilities.
During facility planning, Harberts recognized that to remain competitive -- even in this new, production-friendly environment -- IMS would need to commit to a program of long-term improvement and constant updating centered on advanced automation systems. That is when he turned to MJC Engineering and Technology, Inc, based in Huntington Beach, CA, for the expertise to enhance and automate his metal spinning operations.
MJC manufactures high-tech metal spinning equipment and specializes in CNC retrofit, machine rebuilding, and support for leading manufacturers worldwide.
"The relationship with MJC goes back over 20 years," explained Harberts. "And, about 15 years ago, we bought four retrofit specialty machines from MJC. They came in and set up everything. It was painless.
"We retrofit these older machines including a spinning lathe and specialty machine for venturi panels (special frames used in HVAC applications). MJC helped us to do what we wanted to do with the specialty machine. They figured it out. It was a risk we took together," he said.
Furthermore, "the spinning lathe retrofit from 15 years ago is still paying dividends today because it allows us to produce more and saves us 70-75% in tooling costs."
Repeatable Perfection
"To stay competitive and profitable," said Harberts, "we have to continue to address our equipment and technology issues. We purchased a new SP-3230, 2-axis CNC Metal Spinning Machine about a year and a half ago. The new machine allows us to be more efficient and hold quality better. We've experienced an overall improvement in quality of +25%. The machine takes a circle blank piece of metal, and spins it, cuts the part, and it's done! It's that simple."
Harberts explained that designs are dictated by MJC's customers, with projects turning around in as little as a few weeks, depending on complexity. More complex parts may take up to six months.
"The only learning curve with the new CNC machine was the training, which took about a month. As far as operating the machine, we moved one person from the shop to program the CNC."
All MJC standard, custom built, and retrofitted spinning machines are shipped with the Siemens 840 D CNC System, proprietary SpinCAD software, and include MJC's standard 12-month warranty. Also included is Siemens 2-year extended service contract, and free technical support for the life of the machine. Very little maintenance is required -- said Harberts, "We change the oil every so often, that's about it."
Working Together
"Although we're in the Midwest and MJC is based in California, we work well together. It's as if they were down the street. The Field Support Team has a 'let's see what we can do' attitude," Harberts said. "Our industry is totally changing. Ten years ago, everything was spun by hand. Now, forming is computerized. And, the processes are being continually upgraded so that manufacturing is more transparent and more automated. Now customers can place their order and then follow it right through to delivery by going online to check job status and the stage of production."
Through MJC's pioneering CNC equipment and engineering, IMS makes use of today's most advanced production control technologies. These systems assure IMS customers that their projects are being produced in its U.S. plant with efficiency and high quality, tracked through final production, and shipped on time.
