IJM CNC Machining
Job shop adds machine capacity to stay ahead of the competition
November 1, 2009
Ivan Markovic has seen a lot in his 30 years in manufacturing.
Constantly shifting markets, fluctuating business cycles, and changing technology have all affected the ability of small-business owners to be successful. At these grassroots of the Canadian manufacturing sector, the small-business owner must wear many hats, from owner to operator.
“Each day can definitely bring a new challenge,” said Markovic, “especially these days.”
This Mississauga, Ont., job shop serves the local marketplace supplying parts for custom machine manufacturers. With lot sizes ranging from single digits to the thousands, IJM must remain flexible in its machining capability and labor – something that Markovic has done since starting the company seven years ago.
“It was always my dream to work for myself, and I started on a part-time basis,” he explained. “After four years working in this manner, the business grew to the point where I had to either refuse some work or do it full-time.”
With one Haas CNC machining center in an 800-sq.-ft. space, Markovic entered the world of the small-business owner. Since that time four more machines have been added, all from Haas Automation and all through the machine tool manufacturer’s local representative, Sirco Machinery Co.
“All of our machines have been very reliable, but it really has been the quality of service that has kept me with one machine tool supplier,” said Markovic. “These days shops can lose jobs if they can’t get a serviceman in to do a repair. We simply can’t have downtime because the lead-times on parts are so short these days.”
Growing Organically
Like many businesses, most of IJM’s customers are established, repeat customers, and the rest usually come from word-of-mouth. It’s Markovic’s goal that the part be finished as completely as possible before it goes out the door. That means a part can spend time on the company’s turning centers, milling centers, and boring mill before it is finished.
“In this industry you’re really only as good as your last job,” he said.
Since the company’s early days, it has moved into its current location, which is 5,000 sq. ft., and added more machines to the shop floor. Markovic started adding machining capability almost immediately in 2003, when he added a second CNC machine.
“I had a large order come in and had to purchase another machine,” he said. “Since then I have basically added a new machine each year.”
The latest machine to hit IJM’s floor is a Haas VF-11. This vertical machining center (VMC) with a 120-in. bed adds to the machining capacity of the company in a major way.
“When orders used to come in that involved long parts, I had to farm them out,” said Markovic. “Now I no longer need to and I have more control in terms of price and turnaround time. As soon as you start farming out work, you lose a certain amount of control.”
According to Markovic, a trend in manufacturing these days is the creation of larger, more complex parts.
“The nature of the business is that parts are getting larger and more complex,” he said. “It makes more sense to make one large part than to put together two small parts. There is just less that can go wrong, both during the manufacturing process and also after, during assembly.”
Prior to the addition of the long-bed VMC, the company’s operators had to move long parts around, which had a negative effect on quality. Now, because long parts are no longer moved during the machining process, tighter tolerances can be held.
An added benefit that the company is realizing with this new, larger machine is the ability to do multiples of smaller parts on the machine’s long bed.
Flexible Manufacturing
Even a short visit with Markovic will demonstrate how flexibility plays a large role in the success of the company.
“We focus on doing jobs that need a quick turnaround with high quality and a competitive price,” he said.
What this means is that when he is not working on quoting new jobs, Markovic is busy setting up, running, or unloading a machine. Parts come in as CAD drawings, and the company uses Mastercam to handle the programming. Three employees can do the programming and are also able to run the machines.
“Most of the staff has been here a long time and they are very reliable, especially when we get a large order and we have to put in long hours,” he said.
Importance of Technology
It’s not just acquiring new machines that Markovic calls an essential part of his business. Keeping abreast of new tooling for these machines is equally important.
“There is so much advancement in tooling these days, and it’s important that we use the correct tool for each job,” he said.
The company invests in new tooling to decrease its machining time. For example, one on particular job new carbide tools for high-feed milling enabled the company to increase its metal removal rates to 120 IPM from 20 or 30 IPM.
“It’s very important to stay current with your tooling,” said Markovic. “When we get a new project we will call the supplier to get their recommendations, because in the case of small machine shops like mine, time really is money.”
Setup time is crucial in small-batch manufacturing. That is one reason for the company’s tooling purchases.
“I have bought a lot of tooling so we don’t waste time looking for tools and loading them,” he said. “Even though we are not a large shop, the goal is still to have the machines running as much as possible.”
For more information, visit www.haascnc.com.
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