Ingmar Engineering stands out even more than other fabrication shops in an industry where one metal fabricating shop is rarely an exact copy of another.
The company, which has roots in mould and die making, offers CNC punching, bending and guillotining, welding and assembly as well as the original toolroom machiningfor customers.With its recent purchase of a Hurco VM20 vertical machining center Ingmar are now able to offer more than fabrication related services.
Sometimes it pays for metal fabricators to think outside the boxor, the enclosure to be precise.The production of telecommunications related boxes and similar enclosures are the bread-and-butter jobs for numerous fabricators. They cut the blank, bend it into a box, and weld it up so efficiently that some of the workers probably can do the job blindfolded.
Partners Glen Jones and Errol Liebenberg
But what about the components outside the box? Most fabricators aren’t involved in that. A few, meanwhile, have jumped into the telecommunications and electronics assembly market, where they pull the parts together and assemble the final box before it’s shipped to the customer. And a select few actually make some of the components that accompany the enclosure or boxes.
A little history
Ingmar Engineering, based in Randburg, Gauteng has been in business for more than 40 years. The company derives its name from the first names of the wives (Inge and Martlga) of the original founders Theo and Isaac (an ex partner). Theo and Inge are now retired but still hold a minority shareholding in the business.
Theo (75) arrived in South Africa at the age of 24 after qualifying as a tool and diemaker in Germany. At the time the South African industry needed skilled artisans like Theo and he took the opportunity to emigrate under a government sponsored scheme.
Just arrived on the floor is a new Hurco VM20i vertical machining centre equipped with the WinMAX control. The machine has traverses of X-axis – 1010mm, Y-axis – 508mm and Z-axis –508mm and is equipped with a 4th axis and through spindle coolant.
After bouncing around in industry for several years Theo took the decision to open up his own company in 1974. The business initially concentrated on tool and diemaking and furthered itself to incorporate many different aspects of manufacturing.
Some of the equipment purchased in the early history of the company is still functional in the tool and die area but is now being used more for general engineering activities. This includes a 1971 Mori Seiki conventional lathe, a 1981 Deckel FP 3 milling machine and a Maho universal milling machine purchased in 1984.
“They built those machines to last. They are still in almost perfect condition even though they have been through many hours of work. We work them virtually everyday,” said Glen Jones, who is now a partner and Managing Director of the business.
Glen joined the company in 2002 as design draftsman having trained as an industrial designer. “In those days the company was still very much an ‘old school’ company. Theo had learnt his trade using a drawing board for drawing up plans. He still uses one today because I sought his advice on a project recently and he came back with meticulously drawn up plans with all the detail.”
Components that have been machined on the new Hurco VM20i vertical machining centre
“We have subsequently migrated to SolidWorks for design and other proprietary software for nesting and punching functions.”
“Although it is recorded in the asset register that the company first purchased a Trumpf punching machine in 1982 and subsequently another one in 1988, it was only at the beginning of the century that the focus of the company started to change from tool and diemaking to fabrication of sheetmetal when a Trumpf Trumatic 2000R CNC punching machine was purchased,” explained Glen.
“It was also the company’s first venture into CNC equipment.”
“My arrival at the company brought fresh ideas but I still had to learn the hard way under Theo’s leadership. I do not regret it and both Errol Liebenberg, who is a partner in the business like myself, regard Theo as our mentor.”
A range of buzzbar components that the company has manufactured
“Theo started to relinquish the reigns a bit when both Errol, who has been with the company since 1984, and I were offered shares in the business in 2005, and then in 2007 when the two of us could purchase a majority shareholding onceTheo had decided to retire.”
Different but the same
Even though the business is not your typical metal fabricating operation, Ingmar does share a lot of similarities with its peers, like focusing on the basics – quality and flexibility.
“The company has never really had to advertise. Customers keep coming back and often refer other companies to us. For that type of word-of-mouth promotion to work, the company has to be committed to producing quality parts.”
“For some clients we do production runs from small batches to hundreds. We do not compete in a markets of mass production,but we are able to gear up for specific customer requirements. I believe it is our ability to come up with creative solutions for clients and be able to provide a turnkey finished product for our customers that keeps them coming back.”
The Trumpf Trumatic 2000R CNC punching machine supplied by Retecon Machine Tools
“I cite the example where we had to provide an enclosure for a battery pack and the order would vary between 100 and 150 of these battery packs a month. The battery pack entailed fabricating 24 different components, all fabricated in our shop.”
“Another example is we have now had a number of contracts given to us by a local company that is involved in designing very visual audio, video, lighting, special effects and interactive installations. They have now relied on us to supply all the fabrication and fixturing components that make up their displays.”
“This is very nontraditional fabrication work but extremely rewarding when the dynamic finished installation is there for all to see and you realise you have been part of the creation.”
Telecommunications and electronics industry
“I must admit that, like many other fabrication companies, we do rely on the telecommunications and electronics industries for a large slice of our business. This includes all the major cellphone companies and even Telkom. We do not deal directly with them – our clients do that.”
The Boschert punching machine used for processing copper flat bars
“But we don’t just offer them a box or an enclosure. As far as possible we will give them the complete product. If it entails that we get involved in the design aspect then we will. We will add value wherever possible even if we have to outsource operations like laser cutting and coating.”
“As indicated before we are not limited to these industries to make up our client portfolio. Currently we are involved in manufacturing the fixtures and fittings for the LED lights that are being incorporated into all the Prasa passenger rail cars.”
“We have made enclosures of all shapes and sizes, mounting brackets, medical cabinets, crimping dies, battery stands, distributor boards and rectifier chassis.”
The Amada two metre wide, 80 ton press brake
“With our involvement in these industries we are now quite experienced in providing the buzzbar components for the clients. This is what I mean by adding value.”
Equipment
Besides the Trumpf punching machine Ingmar Engineering have an Elga guillotine which will cut up to 2400mm wide and blank to close tolerances, an Amada two metre wide, 80 ton press brake, a three metre long Adira bending press, a Boschert punching machine for processing copper flat bars and a Haeger riveting machine.
Just arrived on the floor is a new Hurco VM20i vertical machining centre equipped with the WinMAX control. The machine has traverses of X-axis – 1010mm, Y-axis – 508mm and Z-axis –508mm and is equipped with a 4th axis and through spindle coolant.
Ingmar Engineering doesn’t just offer clients a box or an enclosure. As far as possible they will give them the complete product
“We have specifically purchased this machine because of the time it was taking for certain machining operations in our toolroom department. We used to take two and half days to machine 20 of one type of component and now we do 120 of the same component in half a day. We are also aiming to get to the point where we can do the setup for a component and machine it to completion.”
In total the company has 19 staff and operates from a 1500 m² facility, we are proudly South African and currently hold a certified level 2 BEE certificate!
Some of the equipment purchased in the early history of the company is still functional in the tool and die area but is now being used more for general engineering activities. This includes a 1971 Mori Seiki conventional lathe, a 1981 Deckel FP 3 milling machine and a Maho universal milling machine purchased in 1984
“We are not a contract manufacturer although we do have regular clients and components and products to manufacture. We do not manufacture any of our own proprietary products but we do love to become involved in those challenging opportunities from design to prototyping to finished product including all the fixtures and fittings.”
The welding department
Ingmar Engineering supplied a number of components and fixtures for the recently opened The Springbok Experience Rugby Museum at the V&A Waterfront in Cape Town
“We have an old-school approach, courtesy of Theo, but we work well in the “new” era of doing business. Maybe that’s the type of out-of-the-box thinking that keeps the customers coming back to Ingmar.”
For further details contact Glen Jones of Ingmar Engineering on TEL: 011 793 1255 or visit www.ingmar.co.za
