Case Study: How a Leading Automotive Plastic Parts Manufacturer Reduced Waste by 40% with Our Internal-Support Vacuum Suction Cups
Time: 2025-08-20
The Challenge: Perforated Part Handling Was Costing Them Thousands Monthly
Prior to partnering with Suzhou Shuowei Automation Technology Co., Ltd., the client faced persistent issues with their automated injection molding line—specifically when handling perforated plastic sensor housings (each featuring 3–4 holes of 8mm diameter for wiring). Their existing standard suction cups struggled to create an airtight seal, leading to:
- High Waste Rates: 10% of sensor housings (12,000 units/month) were dropped or damaged during demolding, resulting in $12,000 in monthly material losses.
- Production Delays: The line halted an average of 6 times per shift to reposition parts or replace failed suction cups, cutting daily output by 8%.
- Increased Labor Costs: 2 additional operators were assigned to manually handle high-risk parts, adding $5,000 to monthly labor expenses.
“Our sensor housings’ holes were a necessary design feature, but they made automated handling nearly impossible with standard tools,” said [Client Name], Production Manager at the automotive parts firm. “We tried adjusting vacuum pressure and switching to different generic suction cups, but nothing solved the leakage issue.”
The Solution: Custom-Tailored Internal-Support Vacuum Suction Cup Series
After assessing the client’s production line, part dimensions, and pain points, Suzhou Shuowei Automation Technology Co., Ltd. recommended a two-part solution centered on our specialized internal-support technology:
1. Vacuum Expansion Suction Jigs for Sensor Housing Demolding
We customized vacuum expansion suction jigs to match the client’s 8mm hole diameter and sensor housing inner wall dimensions. Unlike standard suction cups that rely on external sealing, these jigs use vacuum pressure to expand a flexible silicone core—gripping the housing’s internal walls securely without relying on the perforated exterior. This eliminated air leakage entirely while preventing damage to the fragile plastic.
2. Internal-Support & External-Expansion Cups for Post-Mold Handling
For transferring parts from the mold to the cooling station, we deployed our internal support & external-expansion suction cups. These cups combine internal stabilization (to keep parts aligned) with external expansion (to seal any remaining gaps), ensuring a consistent grip even as parts cool and slightly shrink.
Both solutions were designed to integrate seamlessly with the client’s existing Fanuc robotic arms and Engel injection molding machines—requiring no major line modifications.
The Results: 40% Waste Reduction & 15% Faster Production
Within 2 weeks of implementation, the client saw dramatic improvements across their operations:
“Within the first month, we recouped nearly half the cost of the new suction cups through waste savings alone,” said [BYD]. “The line runs smoother than ever—our operators no longer spend hours fixing dropped parts, and we’ve even been able to reassign the extra labor to other production areas.”
Long-term, the client estimates the solution will deliver a return on investment (ROI) in 3.5 months and save over $100,000 annually in waste and labor costs.
Why This Worked: Beyond “One-Size-Fits-All” Solutions
The success of this project stemmed from two key factors:
- Customization: Instead of offering generic suction cups, we tailored the jigs and cups to the client’s exact part dimensions (hole size, wall thickness) and equipment.
- Focus on Root Causes: We addressed the core issue—vacuum leakage from holes—by shifting to internal support, rather than trying to “patch” the problem with external seals.
Ready to Solve Your Perforated Plastic Handling Challenges?
This automotive parts manufacturer’s experience is just one example of how [Your Company Name]’s internal support vacuum suction cups transform inefficient processes. Whether you’re dealing with sensor housings, panels, or electronic enclosures, we’ll design a solution that fits your parts, your line, and your goals.
Learn how we can help your business:
“Working with Suzhou Shuowei Automation Technology Co., Ltd. wasn’t just a purchase—it was a partnership. They took the time to understand our unique problem and delivered a solution that worked from day one.” — WU QIU RONG, Production Manager