On
March 1, 2003, Galnik S.A. de C.V. initiated operations of its new
automated zinc plating line in the city of Querétaro in Central
Mexico. The company had been providing electrolytic plating services
since 1988. The growing demand, as well as commitments with its
clients, prompted the company to update its operations.
Some
History
The company was founded in 1988 under the name Maquilas "SAVE,"
offering zinc plating in Querétaro. Over the years, more
than 10 different processes were installed to meet the growing needs
of the market, netting the company annual growth of more than 45%.
This growth has been supported by a culture of quality and customer
service. In 1996 the company was awarded the prestigious Quality
Award from the state of Querétaro, in addition to being certified
ISO-9002.
In January
of 2001, the owners of the company, a family owned enterprise, integrated
their operations with a leading American coatings applicator in
an effort to consolidate and spur growth. However, after the sale,
the acquiring company changed ownership and management, resulting
in a focus away from plating and into powder coatings. The company
had, until 2002, operated zinc and nickel plating baths in a manual
fashion. Quality levels were maintained, but the company was not
keeping up to date with the new requirements from its customers.
A
New Company
In August of 2002, the original owners, in addition to two investors
familiar with the industry, re-acquired the company and Galnik S.A.
de C.V. was formed. The new owners dusted off the expansion plans
and initiated investment in a new facility. The company moved to
a larger, 18,000-sq-ft plant and built and automated dual-hoist
zinc plating line with the help of a local supplier, Eppesa. The
line has the ability to provide multiple chromates, including trivalent,
in both rack and barrel.
"The line
has 38 stations, with immersion degrease, electrolytic degrease,
activation with eductors, zinc plating, chromates and air dry,"
said Renato Villaseñor Mendoza, operations manager. The plating
chemicals are from Enthone.
With this equipment Galnik will provide zinc plating in both rack
and barrel, with trivalent chromate, yellow chromate, olive green
chromate and black chromate. Auxiliary equipment includes tanks,
rectifiers and hoists.
From the previous
facility, a semiautomatic nickel-plating line has been upgraded,
as well as a tin line, a reel-to-reel nickel-plating line, zinc
phosphating and electropolishing of stainless steel. The facility
also has an automated cleaning line for stamped parts, in a process
in accordance with regulations for food products.
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New
plating line for finishing parts at Galnik in central Mexico.
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Benefits
Gained
"The
automation," stated Renato Villaseñor, "has eliminated
the possibility of human error, increased efficiency and productivity,
as well as the consistency and homogeneity of our plating and current
distribution. In addition, Galnik has obtained processes and chemical
cycles at the forefront of current technology, in accordance with
customer's needs."
The automated
line has tripled capacity and increased production efficiency. Since
startup in the first quarter, the company is producing in one shift
what it needed three shift to accomplish in the past. Working at
25% of its capacity, the new equipment has reduced labor needs in
half. Two workers can now perform 100 - 200% more work than was
done by five. Given the cost reductions and increase in productions,
Villaseñor expects to see a return on investment that will
allow the company to continue to grow into new processes.
New
Horizons
Galnik serves the burgeoning automotive parts industry in central
Mexico. The company expects to capitalize on this growth and be
producing at full capacity within the next three years. The existing
floor space, in addition to the modular design of the line, will
allow Galnik to add incremental capacity at its existing plant.
Galnik's expects to serve customers in a 300-mile radius of its
facilities, which includes automotive OEMs and Tier 1 suppliers
in San Luis Potosí, Silao, Puebla and Toluca. The company
will also explore geographic expansion as needed by current or potential
customers.
The improvements
do not stop at production, but also include upgrades in Galnik's
quality system. The company is pursuing ISO 9000:2000 certification
this year, and in 2004 to have obtained TS-16949. In the environmental
arena, Galnik has a wastewater treatment facility and will seek
ISO-14001 certification before 2005. Thus, Galnik continues to respond
to a compromise of growth and quality made to its customers.
