Customer Background
Customer: Dongguan Youhua Auto Parts Co., Ltd.
Industry: Automotive parts manufacturing
Production Scale: 8 assembly lines, producing 2,000 wiring harness assemblies per day
Soldering Process: Lead‑free soldering at 390°C
Pain Points & Challenges
The customer had been using original Japanese Hakko TX2 series automatic soldering tips and faced the following issues:
High procurement cost: Each tip cost RMB 325, with a monthly consumption of 100 pieces – a monthly expenditure of RMB 32,500 on tips alone.
Long lead times: Ordering original tips required 4–6 weeks in advance, creating high inventory pressure and occasional stock‑outs that disrupted production schedules.
Our Solution
After receiving the customer’s request, we took three actions:
On‑site assessment: Our technical team visited the production line and found that the customer mainly solders copper wires ranging from 0.5 mm² to 2.0 mm², which places high demands on tip wear resistance.
Targeted recommendation: We recommended our nano‑composite coated TX2‑XDR6 soldering tips, featuring a coating thickness of 150 μm (compared to 120 μm on the original product), specially optimised for continuous soldering operations.
Free sample trial: We provided 20 sample tips free of charge for a 3‑week comparative test on the customer’s Line 2.
Quantified Results
After three weeks of real‑world testing, the comparison data are as follows:
| Parameter | Original Imported Tip | Our Tip | Improvement |
|---|---|---|---|
| Unit purchase price | RMB 325 | RMB 180 | 45% lower |
| Average service life | 7,500 solder joints | 8,500 solder joints | 13% longer |
| Monthly consumption | 100 pieces | 88 pieces | 12% fewer |
| Monthly consumable cost | RMB 32,500 | RMB 18,000 | 45% saved |
In addition, the customer reported significantly improved soldering consistency. The defect rate caused by tip wear (cold solder / poor joints) dropped from 1.2% to 0.45%.
Customer Testimonial
“To be honest, we were sceptical at first – we had tested many domestic tips from other suppliers and were never fully satisfied. But after the actual trial, the life and soldering performance of your tips completely exceeded our expectations. We’ve now switched all eight lines over, and we’re saving more than RMB 65,000 in total annual costs.”
— Mr. Chen, Production Supervisor, Dongguan Youhua Auto Parts Co., Ltd.
