Fabrication Stamping Machining Electrical Assemblies Custom manufacturing & value-added services
imsmfg.com IMS Companies LLC is a consolidation of contract manufacturing operations working together to provide Innovative Manufacturing Solutions to OEM s in sourcing component parts and assemblies. The value-added services provided by the IMS group include tooling, metal stamping, sheet metal fabrication, machining, cable assemblies, wire harnesses and sub-component assembly for leading manufacturers in the appliance, automotive, electronics, medical and industrial equipment industries. Supporting the broad range of services offered by IMS are years of experience in contract manufacturing inherent in each operation, the skills and talents of tool builders and engineers expert in their specialties, hard won reputations for quality and service and a cooperative engineering involvement in customer product development. Every IMS operation, working individually or as part of the group, provides project support ranging from original concept actualization to product design and prototyping to final production. Global Manufacturing The synergistic business strategy of IMS is to provide the highest quality of services to customers through inter business alliances with suppliers and vendors as well as through intra company cooperation in sharing skills, talent and capabilities. The result is a business entity that is able to service global accounts more efficiently and with a cost effectiveness that single focus companies cannot match. Manufacturing Capabilities Integration & Engineering Superior CAD design software, including Auto CAD 2002, CATIA V5, ProE 2000 and SolidWorks systems enables IMS engineering to communicate effectively with customer engineers. Lean manufacturing initiatives in each IMS operation results in lower manufacturing costs and assured competitiveness. Quality Assurance IMS companies have earned top certifications for the industries they serve. These certifications include TS 16949, QS 9000, ISO 9001:2000 and ISO 14001. Each IMS company has been recognized as a key supplier or best in its commodity category by its major OEM customers. Supply Chain Management A VANTAGE ERP system links all the IMS operations ensuring quick response to customer requirements through flexible and responsive process technology. Inventories are managed and maintained using KANBAN and JIT planning techniques. EDI and Web based Internet ordering systems are in use throughout the IMS family and capable IT systems are in service to meet any customer information exchange or order-processing requirement. Experience matters in contract manufacturing operations. Each of the IMS companies possesses a long and successful record of achievement. Supported by this record of success, their services are the finest the contract manufacturing industry has to offer. These services include precision progressive die metal stamping, tool design and build, prototyping, superior sheet metal fabrication (especially in stainless steel), special machining services for gears and high volume machined parts and the design and assembly of complex wire harnesses and cable assemblies. Buhrke - Precision metal stampings & assemblies IMS Buhrke has been an industry leader in supplying the automotive, appliance, electronics and industrial market segments since 1949. Buhrke features exceptional engineering ability in developing automated component assembly systems. Pgs 4-7 Global Gear & Machining - Contract machining & sub assembly services IMS Global Gear & Machining specializes in the contract manufacture of mid to high volume quantities of gears and other precision components. Automated CNC work cells are used to produce helical and spur gears for transmissions along with pulleys, shafts and hubs for other industrial applications. Pgs 12-15 EXTON - Sheet metal fabrication & electro-mechanical build & test IMS EXTON utilizes the latest sheet metal fabricating equipment to provide increased process capability, lowered processing costs and reduced over-all cycle time in sheet metal fabrications and assemblies for a wide range of OEM customers. Pgs 8-11 Electrol - Custom wire harness & cable assembly IMS Electrol has been providing high quality assemblies since 1962. Early engineering involvement available from IMS Electrol results in improved manufacturability and efficiency, thus providing the lowest available cost. Pgs 16-18 2 3
Precision Metal Stampings & Assemblies A recognized leader in the manufacture and assembly of precision metal stampings and assemblies since 1949 IMS Buhrke serves the automotive, appliance, electronics and industrial equipment industries. The company, since 1949, has been recognized as an industry leader in the development of automated assembly systems designed for the efficient and least costly manufacture of complicated mechanical assemblies. IMS Buhrke is certified to TS 16949, ISO 9001:2000 and ISO 14001. Company operations are located in Arlington Heights, Illinois and Monclova, Coahuila, Mexico. Drawn Parts Assemblies Brackets & Covers Terminals & Connectors Shielding Air Bag Components IMS Buhrke operates press equipment ranging in size from 30 to 600 tons and includes Bruderer and Minster presses. Supporting the stamping operations is a large and superbly equipped tool room. IMS Buhrke builds and maintains its own progressive dies, many of which are up to 120" long. Five Charmilles EDM machines and Mazak machining centers, along with a variety of milling and grinding equipment give IMS Buhrke the ability to handle virtually any tool build requirement. IMS Buhrke is about people. The skills, experience and enthusiasm of a staff of 150+ employees, including over two dozen full time toolmakers, is what drives the company to success and growth. 4 5
Precision Metal Stampings & Assemblies A recognized leader in the manufacture and assembly of precision metal stampings and assemblies since 1949 IMS Buhrke employs the most modern technological tools to achieve the highest level of efficiency. Every IMS Buhrke tool has in-die sensoring installed to eliminate crashes and avoid costly downtime. Furthermore, the company utilizes multi sensor, high accuracy metrology vision and touch probe systems in its production and quality departments. Upgraded press control units are installed on every press thus enabling the press to accommodate virtually any type of sensor. The latest gauging and measuring instrumentation, supporting SPC data collection, are also employed. Preventative maintenance is a way of life at IMS Buhrke. A full time, on line press monitoring and maintenance scheduling system, developed in-house, has received widespread recognition as a leading edge application in the metal stamping industry. Through strict quality assurance programs, IMS Buhrke attained ISO 14001 certification in 2002 and TS 16949 certification in 2003. IMS Buhrke boasts exceptional engineering talent that is supported by the latest CAD software including Auto CAD, CATIA, ProE and SolidWorks. Engineering support is available for product development, tool design, prototyping and project management. IMS Buhrke is recognized for its capability to eliminate costs in secondary operations through the use of automation and in-die processes. Staking, tapping, welding and component assembly are processes the company has built into production tools that reduce the costs of secondary operations. Further savings are realized through the use of various automated assembly systems, built and designed by IMS Buhrke, that reduce the amount of labor involved in the fixture, assembly and check control of multi-part assemblies. 6 7
Sheet Metal Fabrication & Electro-Mechanical Build & Test Quality Sheet Metal Fabrication & Electro-Mechanical Assembly Design, Build, Test IMS EXTON is an ISO 9001:2000 certified sheet metal fabricator serving the appliance, electronics, telecom, safety & security and transportation equipment industries since 1974. Investments in the latest production technology, combined with top quality technical support and design services, make IMS EXTON an outstanding source for custom sheet metal fabrications and value-added assemblies. Kiosk Testing Equipment Transportation IMS EXTON production systems are designed to increase process flexibility, lower processing costs and reduce manufacturing cycle time. Flexible manufacturing systems utilizing N.C. lasers, turret punch presses and blanking shears result in better material utilization and efficient packing of complex parts. A computer network controls multiple press brakes from a central file server to reduce set up times and ensure top quality parts. IMS EXTON specializes in the design and build of complex housing and cabinet assemblies. A major portion of the company s facility is dedicated to the assembly of complete electrical and mechanical products to exacting customer requirements. Responsibility for painting, finishing and testing of PCB s in an ESD protective environment is assumed by IMS EXTON as part of the manufacturing cycle. A JIT stocking program ensures delivery of defect free products to customer docks on time, every time. Security Communications Sheet metal fabrications from small electronic housings to large equipment cabinets. 8 9
Sheet Metal Fabrication & Electro-Mechanical Build & Test Quality Sheet Metal Fabrication & Electro-Mechanical Assembly Design, Build, Test IMS EXTON engineering works closely with customer designers in an Early Supplier Involvement (ESI) design program that substantially reduces tooling and direct product costs. IMS EXTON company offers manufacturing design, tool design, cost reduction assistance, original product concept actualization and prototyping as services that lead to successful final production. Files can be transmitted using a wide range of formats including IGES, DXF, DWG and CAD KEY. CAD software capabilities include Auto CAD and ProE. IMS EXTON offers many special capabilities that exceed customer expectations from conventional metal fabricating operations. The production and finishing of stainless steel parts and assemblies are well-developed manufacturing process skills at IMS EXTON. IMS EXTON features tight quality control. Real-time SPC measurements, administered by trained operators at their stations, monitor critical dimensions as parts are being manufactured. In-process controls, calibrated equipment and testing capabilities are employed at IMS EXTON. MIG and TIG welding services are used to fabricate products, from the complete fabrication of large stainless steel cabinets and housings to roll cage assemblies for lift trucks. Secondary operations for parts assembly include welding, fastener insertion and various types of mechanical joining. 10 11
Contract Machining & Sub Assembly Services Contract High Volume Machining Services; Precision Gears & Components IMS Global Gear & Machining specializes in the custom manufacture of mid to high volume gears and other precisionmachined components. The company is certified as ISO/TS 16949:2002 and ISO 9001:2000 and serves primarily as a Tier One and Tier Two supplier to the heavy equipment and transportation industries. IMS Global Gear & Machining is a wellknown and proven choice for the design and manufacture of helical gears and pulleys for engines and fuel pumps. Applications for other products include helical and spur gears for transmissions as well as complete assembly of multi-part components into finished modules. IMS Global Gear & Machining is housed in a 132,000 sq.ft. facility in Downers Grove, IL and utilizes a combination of automation and CNC equipment for a wide range of machining. Operations include turning, hobbing, grinding, broaching, balancing, drilling, milling, threading and heat-treating. The equipment set-up includes dedicated lines for exacting precision and cost efficiency. A continuing reinvestment program means IMS Global Gear & Machining has the latest equipment to provide the best cost/value and the capability to meet specialized customer needs. IMS Global Gear & Machining offers capabilities to manufacture both spur and helical gears (external) in the following range sizes: Max. diameter 12", Max. width 6" Max. helix angle for helical gear 42 o Max. gear module (min. DP) 8 (3.175) Typical product end use includes crankshaft, camshaft, auxiliary drive, oil pump, fuel pump, upper and lower idler gears as well as various spur gears. Turned, drilled and milled components include D drives, flywheel adapters, crankshaft flange adapters, sprockets, ID/OD splines and belt drive pulleys. IMS Global Gear & Machining has delivered over 10,000,000 gears without a single performance problem, less than 40 ppm. The company has experienced 100% on-time delivery for 8 consecutive years. 12 13
Contract Machining & Sub Assembly Services Contract High Volume Machining Services; Precision Gears & Components IMS Global Gear & Machining inventory management systems are in place to ensure a JIT supply of parts. Rapid prototyping, quality tooling and complete manufacturing process implementation are factors that help ensure quality components in high volumes. IMS Global Gear & Machining products meet customer requirements for performance, lifespan, noise reduction, weight and cost. IMS Global Gear & Machining engineers work with customer engineering and manufacturing teams from the early design phase through the entire component manufacturing process. The company will design a production process to match precise customers needs and specifications from the first run to the end of product life cycle. IMS Global Gear & Machining helps customers increase operational efficiency. Modular assembly and inventory management are post production steps that the company will assume thereby relieving customers of the responsibility. After assembling various components into a sub component assembly, IMS Global Gear & Machining will maintain stocking levels to ship just-in-time. By using the latest web-enabled technologies, IMS Global Gear & Machining can seamlessly integrate into a customer s inventory management process. IMS Global Gear & Machining will manage customer returnable packaging. IMS Global Gear & Machining is committed to producing the highest quality precision gears and components in the industry. As a TS16949 certified facility, using Statistical Process Control and computer scheduled calibration tools, the company guarantees products will meet rigorous standards in noise, weight and performance. Every gear made by IMS Global Gear & Machining is precision machined to ensure exacting tolerances and the greatest possible lifespan. 14 15
Custom Wire Harness & Cable Assembly Custom Cable Assemblies, Wire Harnesses & Electro-Mechanical Assemblies IMS Electrol has been providing custom cable assemblies, wire harnesses and electro-mechanical assemblies since 1962. The company serves a wide range of customers in various industries, including industrial, medical, analytical instrumentation and others. Quality, on-time delivery and service are driving forces at IMS Electrol. The focus on quality is evident through the attainment of ISO certification in 1996, and the training and testing of all production personnel to the IPC/WHMA-A-620 specification. 100% testing of all assembled product is continually performed. On-time delivery is maintained through Vendor Managed Inventory (VMI) programs at the customers facilities, Kanban systems and a constant monitoring of shop floor activity. Service is provided, as needed, from a product s concept stage through the delivery of production parts. The IMS Electrol engineering staff has extensive experience in providing cost-effective alternatives, rapidprototyping and short-run needs. Web-based ordering is also offered as an efficient method to place an order in the system. Capabilities include: Multi-Conductor Cabling, both high and low density Insulation Displacement Connections (IDC), including flat cable and discrete wire Crimp-and-Poke Connectors Wire Harnesses from two wires to hundreds of wires Value-added Processing of Components Soldered Cable Assemblies, interfacing to connectors, circuit boards & components Electro-Mechanical Assembly and Testing, small box builds to large control panels Certifications include: ISO 9001:2000 registration from Underwriters Laboratories CSA and TUV certifications Multiple certifications from customers IMS Electrol customers appreciate the high level of involvement in their engineering processes. The IMS Electrol staff constantly offers alternatives to simplify manufacturing operations, improve cost and increase product reliability. Heavy Gauge Power Wiring: as large as 750 MCM Integrated Cable Assemblies containing multiple connection methods Wire Processing on multiple automated systems. Also can provide tube cutting and blunt cutting The engineering staff has accumulated knowledge through many years of experience, close relationships with suppliers and constant evaluation of new component offerings. 16 17
Custom Wire Harness & Cable Assembly Custom Cable Assemblies, Wire Harnesses & Electro-Mechanical Assemblies IMS Electrol believes its workforce is its most valuable asset. From the moment a customer contacts the company to request a quote, place an order or discuss their design, the IMS Electrol level of commitment is evident. The IMS Electrol Purchasing Department works closely with suppliers to maintain strategic pricing and a timely supply of raw materials. Production schedules are posted to optimize the workforce of over 100 dedicated people. Quality is paramount throughout the various operations, from wire processing and assembly to shipping. IMS Electrol is a member of the Wire Harness Manufacturer s Association (WHMA). This membership allows access to the vast resources available through WHMA, translating into better manufacturing methods and cost effective pricing. IMS Electrol is committed to quality assemblies, delivered ontime, at the best possible price. The company strives to provide its customers with the optimum solution to meet their cable assembly, wire harness and electro-mechanical assembly needs. 18
128 North Lively Boulevard Elk Grove Village, IL 60007 Ph: 847.439.7007 Fax: 847.439.7040 www.imsmfg.com info@imsmfg.com Buhrke Industries LLC 511 West Algonquin Road Arlington Heights, IL 60005 Ph: 847.981.7550 Fax: 847.981.0772 www.buhrke.com info@buhrke.com Global Gear & Machining LLC 2500 Curtiss Street Downers Grove, IL 60515 Ph: 630.969.9400 Fax: 630.969.1736 www.globalgearllc.com info@globalgearllc.com EXTON Corporation 128 North Lively Boulevard Elk Grove Village, IL 60007 Ph: 847.439.7007 Fax: 847.439.7040 www.extoncorp.com info@extoncorp.com Electrol Company, Inc. N77 W30924 Hartman Court Hartland, WI 53029 Ph: 262.966.3741 Fax: 262.966.7021 www.electrolmfg.com info@electrolmfg.com