Written by Kerryn Caulfield, Executive Director, Composites Australia Inc.
Founded in 1978 with a modest investment and unwavering determination, Martin and Krystyna Nikolas embarked on a venture that became a leading force in the composite manufacturing industry. While Martin furthered the company through research, development and innovation in materials and processes, Krystyna’s talents tilted towards management, compliance and financial control ensuring the company operated with rigor and efficiency.
The Nikolas family’s involvement in the company now spans generations, with their sons, Stefan and Thomas Nikolas, playing vital roles in maintenance, engineering, manufacturing as well as the day-to-day running of the business. From the two original employees to a strong, skilled workforce of almost 80, Marky Industries’ evolution is an account of continuous improvement and community.
The company grew into an industrial force, manufacturing a wide range of industrial composite components serving sectors as diverse as architecture, rail, construction, agriculture, marine and recreation. However, the core of Marky’s business focus has been on serving the transport industry with quality and efficiency for many decades. From bonnets and sleeper boxes to dash assemblies and engine covers for a range of transport manufacturers including Mack, Volvo, Iveco, Ford, Western Star, Navistar, and Cat Trucks, Marky has consistently delivered products that marry materials, form and durable function.
In the competitive field of heavy transport manufacturing, the importance of robust systems such as Just in Time (JIT) and Quality Management Systems (QMS), particularly the ISO 9001:2015 (formerly 2008) standard, is paramount. These frameworks are critical for managing production efficiency and quality. Marky’s role as a key supplier to Ford before its production moved offshore, providing 26 components per truck and up to 16 truck sets per day including bonnets, engine covers, and dash panels, showcases the bearing of these systems. Krystyna highlights that implementing such systems was key to securing and expanding their business, emphasising that JIT and a commitment to continual improvement are crucial for meeting customer needs precisely and efficiently. Both systems and an open mind to continual process improvements, Krystyna believes are symbiotic and essential.
Krystyna emphasises that within the QMS, ‘Quality Gates’ play a pivotal role. Located at the end of each production stage, these gates serve as essential checkpoints. Here, both products and processes undergo scrutiny based on specific criteria before moving forward. This methodical strategy fosters a cycle of continuous evaluation and enhancement, facilitating the early detection and correction of any potential issues, thereby streamlining the production process.
The company’s production teams have been trained in specialised compliance and monitoring for all critical process steps of the composite production process, including:
- Gelcoat Application: Precision in the initial layers ensures superior surface finishes.
- Infusion Process: A meticulous approach to achieving optimal structural integrity.
- Assembly Line: Careful integration of parts to form a cohesive, high-quality end product.
- Final Finishing: Detailed inspections to guarantee that each component meets both aesthetic and functional standards.
The shift towards reusable silicone vacuum bag technology around eight years ago marked a significant milestone for the company, enhancing efficiency and the aesthetics and durability of their core products – particularly truck bonnets. Continuous improvement of the process has reduced material consumption, produced consistent quality across parts, decreased use of consumables, reduced waste and enables quicker turnaround times. Eliminating the need for release agents and maintenance further streamlined operations, contributing to a more efficient and sustainable manufacturing process. Zero reject rates of bonnets over a 24-month period is a validating accomplishment.
Though initially a challenging process, instituting JIT and QMS made Marky Industries acceptable to international companies and subsequently opened the door to more clients, some of which the company still serve today. With an emphasis on local manufacturing, Mack Trucks Australia is one such client that began integrating composite materials into their truck cabs in the early 1980s, as part of the industry’s broader shift towards lighter, more durable materials that offer improved fuel efficiency and performance. Composite materials, which include fiberglass and carbon fibre, have been used for various cab components, such as hoods, fenders, and sleeper boxes, to reduce weight without sacrificing strength or durability. In 2021, Marky was called to gear-up to make the exterior cab body parts for Macks’ revamped models including the Titan, Super-Liner, Trident, Metro Liner and Granite, all of which serve a diverse range of handling and haul operations.
Trucks represent more than just vehicles; they are significant investments, serving dual roles as workplaces and living quarters. Owners and drivers rightly take pride in their rigs, personalising them with custom parts, accessories and creative paint jobs. Targeting this market, Marky Industries recently released a custom after-market bonnet for the Mack Superliner and Titan models. Available in both round and square guard models, along with custom grille assemblies and headlights, these bonnets are a cool enhancement – supplied, painted and fitted to the customer’s vehicle.
COVERING ALL BASES
Trucks are just one market served by this diverse composite specialist that also has close to 50 years’ experience manufacturing products for the mining, transport, construction, chemical, defence, and recreation and building industries. Central to Marky Industries’ ideals is the belief in the strength of a robust local supply network and a proficient manufacturing sector, evident through his involvement in the composites community through Martin’s roles at PARTEC (the Plastic and Rubber Technical Education Centre) and with Composites Australia Inc. as a Board member since 2013 and Vice President since 2014.
