Supporting global automotive brands with production-ready functional components—
designed for consistency, scale, and long-term program stability.
- Long-term mass production program
- Multi-material component solution
- Delivered across multiple vehicle platforms
- Stable supply for global OEM standards
Customer Background
The customer is a global automotive OEM / Tier-1 supplier, operating high-volume vehicle programs with strict requirements on:
- Quality consistency
- Production stability
- Change control
- Long-term supply reliability
The components were used in series production vehicles, where failure or inconsistency was not an option.
Industry Challenge
As vehicle platforms evolve, functional components face increasing demands:
- Multiple materials combined into a single part
- Tight tolerances across high-volume production
- NVH, sealing, insulation, and thermal requirements within limited space
- Frequent design changes during development and ramp-up
Previous sourcing approaches led to:
- Inconsistent quality between batches
- High coordination cost across multiple suppliers
- Uncertainty during volume ramp-up
The customer needed a supplier who could own the integration—not just one process step.
Sanken’s Approach
Sanken was engaged not just as a parts supplier, but as a manufacturing partner.
From early-stage discussions, our role focused on:
- Material selection and functional optimization
- Manufacturability evaluation for mass production
- Process integration across converting, die-cutting, and molding
- Risk reduction before volume ramp-up
Our objective was simple:
Make the component predictable in mass production.
The Solution
Delivered Solution Included:
- Custom functional components combining foam / rubber / adhesive materials
- Precision die-cutting to ensure dimensional accuracy
- Controlled molding and bonding processes
- Standardized production parameters for repeatability
- Assembly and kitting aligned with the customer’s production line
All processes were designed to support:
- Stable output
- Controlled variation
- Clear traceability
Results & Impact
Measurable Outcomes:
- Stable mass production across multiple vehicle programs
- Improved consistency compared to previous sourcing
- Reduced supplier coordination complexity
- On-time delivery aligned with automotive program schedules
Customer Impact:
“The solution enabled us to move from prototype uncertainty to stable series production.”
Why This Case Matters
This project demonstrates what automotive OEMs value most:
- Not just technical capability—but production discipline
- Not just low cost—but long-term reliability
- Not just samples—but scalable, repeatable manufacturing
It reflects how Sanken supports automotive programs—from development to mass production—without adding risk downstream.
Built for Automotive Standards
- Automotive quality systems (e.g. IATF 16949)
- Multi-site manufacturing support
- Process control & traceability
- Experience with long-term automotive supply programs
Planning your next automotive program?
If you are looking for a manufacturing partner who understands
automotive production reality—not just specifications,
we are ready to support your next project.