Indiana Company Leading The International Market Through Technology Investment

In small-town northeastern Indiana, in the heart of US agriculture, is B&J Specialty, Inc. First glance at the surroundings does not give new clients a clue that they are about to enter a world-class mold-making operation. But that is exactly what they find.

The business has come a long way from when it was founded more than 25 years ago by Robert, Norma and John Wicker in the family garage, from doing basic machine work and repair to building and modifying the specialty molds and dies they encounter today. Now employing more than 50 people, the operation does work for the automotive, medical, electronic and consumer products industries.

Some of the molds that B&J produces are small enough to fit in the palm of your hand. Others weigh up to 30,000 pounds and need to be carried by one of the company's three cranes, the largest being 15 tons. B&J has seen its own big results in just a short time due to an investment in Makino technology.

The need for speed and technology brought B&J to purchase its first Makino machines. EDM manager Corey Boese had experience working on a Makino machine at his previous job. It was this experience that assisted owner John Wicker in deciding to check out the Makino line.

This decision has cut nearly 70 percent off the company's cavity and core production time, while maintaining superior quality and finish. In other cases, B&J knocks anywhere from two to three minutes off per part, and gains a volume savings of up to 35 days of production.

Speed and Technology [back to top]
After looking long and hard at different graphite and milling combinations, B&J purchased the Makino SNC64G/S graphite machining center and the EDNC43S Ram EDM machine.

"A year later we had more sinker work than we could keep up with so we also purchased the Makino EDNC65 Ram EDM," said Boese. "Then, a few months ago, we had a real need for a true highspeed machine to use for hard cutting steel. We picked up the Makino V55 vertical machining center."

The addition of the Makino machines has really made an impact on B&J's operation. Boese recalls a mold that the company machined for a PVC pipe elbow.

"With the old process we would set up the fixture and then put it in the milling machine and rough everything down. Next, we would send it out to heat treat. After heat treating, we would grind the face, set it back up in the CNC mill, finish mill it—utilizing far too many cutters in the process—then spend an extensive amount of time polishing until complete.

"But we discovered on the SNC64G/S, we were able to set up and cut a solid block of hardened tool steel as well as graphite. Everything could be done in the same machine at one time. The piece is primarily complete and ready for assembly. If it is a more detailed mold with sharp corners, we might do some fine work on the EDNC65 sinker machine. But then we are done. We have found that the time savings is significant."

EDCAM and Superspark Processes [back to top]
B&J is also using advanced technology like Makino's EDCAM Professional™ and SuperSpark™ to get better results.

The EDCAM software relays critical data between CAD-CAM systems and sinker EDM machines, bypassing the need for manual input that often leads to operator errors and mistakes. "With EDCAM, I know that before I even cut an electrode, the machine will kick out the best burn plan. We then incorporate that plan into the manufacturing of the electrodes. It simply eliminates setup time and improves accuracy," said Boese.

Similarly, B&J uses Makino's SuperSpark EDM technology with the EDNC43S machine. This process reduces rough machining time up to 60 percent, regardless of the shape, size or cavity depth. This dynamic power supply adjustment option for MGF control machines can save an average machine shop as much as $18,000 per year based upon typical volume and hourly rate estimates.

"Now with Makino we can do things over a couple of days, in many cases with a savings of over 70 percent."

"This is a great ensemble of technology— you can see a noticeable difference in what it does for you," said Boese. "You can set the machine to run, and if it can be more aggressive in making its cuts, it does so automatically. It really makes a difference for unattended machining over the course of a couple days."

Globally Competitive [back to top]
This investment in technology, in combination with the machines, really makes the difference in B&J's success.

"The old way we did things took almost two weeks or more," said Boese. "Now with Makino we can do things over a couple of days, in many cases with a savings of more than 70 percent. That is unbelievable. In other areas, we knock off anywhere from two to three minutes per part, times 17,000 parts—a significant savings of production time in such materials as auto parts, electronic parts, medical parts, consumer goods and PVC elbows and piping.

"This has enabled us to have a shot at being competitive in the global marketplace. Now we feel that we are utilizing machining techniques that are ahead of the industrial curve. The amount of time that we have eliminated is just awesome, and this savings allows us to put even more work through our shop."

With the savings in machining time, B&J has had the chance to further expand its business. "In tough economic times we have continued to grow our shop by adding equipment and people, which in turn has enabled us to take on more work. Just because we can now do a two-week job in two days does not mean we can take a vacation—we fill that time with two more weeks of work," said Boese.

Leadership at the Top [back to top]
Boese credits the company's success to owner John Wicker for thinking outside of the box when it comes to investing in the right tools for the job. His leadership is felt at the core of the operation.

"John is continuing to prove that we can work in a global market and that we can be competitive. He has gone out on a limb in this rough economy to invest in this kind of technology. At the same time, he gives people like me the opportunity to be involved in the decision-making process. This management style makes everyone feel like they are part of the same team, and makes a big difference in our success," said Boese.

"I seriously believe had we not invested in this technology, we would have run the risk of falling behind in a technologically driven market. However, it takes more than money to invest in this kind of technology. It also takes people who are willing to get in there, roll up their shirt sleeves and try new things. As a company, we are doing things a new way, which is faster and more efficient. It has gotten us to where we are today. We can compete globally in this kind of economy, and we appreciate that."

Productivity Throughout [back to top]
B&J employees appreciate the success that has come from investing in the new machines, as the productivity they provide fuels the organization, and keeps the company's customers happy.

"We know it is essential to continually improve ourselves and our processes, giving our customers what they need so they can also be competitive in the years to come," said Boese. "We demonstrate our technology to our customers and explain how it will give them a better product.

"We will continue to look at the type of support we get with our machines when choosing new equipment."

"Our clients may know that these are very advanced pieces of equipment, but when you actually show them what you can do for them with these machines, it makes a difference. They wouldn't be coming back to us, and we wouldn't be growing and thriving if it was not for what we can do with this equipment. We are literally working hand-in-hand with our customers— as a partner on their projects. We want things to work for them. It is beneficial to all of us."

Makino Partnership [back to top]
B&J and its employees are also satisfied with the quality of the equipment and the support they receive.

"I am happy with the lack of down time, in addition to the rigidity and the sturdiness of the machine," said Boese. "Had you told me when I was 20 years old that I was going to take a machine that could cut graphite, and also use it to cut a hardened piece of D2 tool steel at those kinds of feedrates and not hurt that machine, I would have told you there is no way. What we are able to do with our Makinos is astonishing."

"One of the things I have always said is there are a lot of similarities in machine tool capabilities. But what really separates Makino from the others is the knowledge and the passion of their employees. If you go to a manufacturer school—such as EDM School—the competitors teach you how to run their machine and that is it.

"When you go to Makino, they teach you how to think outside the box—how to look ahead. They show you how to make sure that you are approaching your cutting in the right way. They make sure you are thinking about what kinds of cutter paths you're going to be using for hard cutting, and what you should rough out ahead of time. They show you what kind of electrodes to manufacture and how to manufacture them. It really makes a difference in your success with that machine."

Predicting a Successful Future [back to top]
"It has been amazing for us in the past 10 years to have gone from being an eight-man shop in the middle of nowhere to a substantial player in the corporate market. It is a great experience to have people like Makino working with us to make it possible," said Boese.

"We will continue to look at the type of support we get with our machines when choosing new equipment. How well is it going to hold up? Is it a machine we can still use five or 10 years down the road? We will continue to look at capabilities and price."

"I definitely see B&J's future as being successful," said Boese. "I see us building even bigger tools and having a larger engineering staff, having more software and programmers and spending a lot more on technology. I see us growing significantly larger than we are now, and continuing to be progressive and aggressive. And, I see us maintaining our relationship with Makino."

B&J is continuing to grow, quite literally, out of the farm fields and into the global arena.

For additional information about B&J Specialty, Inc., and the company's expertise in dies, molds, EDM, and CNC/3-D machining, contact Dan McMaken at 7919 North 100 East, Wawaka, IN 46794. Or, call him at 260-761- 5011, fax: 260-761-5861, or e-mail him at sales@bjspecialtyinc.com.

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