Case Study
How Miles Products helped DECKED introduce their market changing product.
The team at DECKED came to Miles Products with a great product concept and unique challenge. We are proud to have helped them realize their vision and win the war on disorganized trucks everywhere!
Background
Jake Peters and his buddies liked to work on their trucks. They wanted the vehicles to serve their needs as best as possible, whether for fun or work. This meant organizing all the cargo, for whatever the next task or adventure might be.
After experimenting (and battling) with homemade wooden drawers, and storage compartments made of plywood, dimensional lumber and big box store hardware, they knew there had to be a better way.
What started out on a napkin in a local diner, evolved into 3 years of R&D and two full-length, weatherproof, 2000 pound payload retaining, 100% American made pickup truck storage systems.
DECKED was born!
Challenges
DECKED knew that manufacturing success would be key to their future. However, product development and manufacturing was unfamiliar territory to their key managers.
They needed partner companies who could contribute with competitive pricing, design for manufacturability expertise and a proven commitment to service and quality.
Company founder, Jake Peters, had a strong new product concept and had identified structural foam molding as a potential material and process for the job.
After discovering Miles Products via a Google search, Jake called Bruce Miles and cautiously floated the idea over the phone. He had two big concerns. How much would it cost? And, can it be done?
The finished product performance had to be as rugged and hard-working as the workers and outdoor sports enthusiasts who made up their target market.
Jake had a number of must-haves plus a wish list.
The DECKED product had a significant bill of material including:
- Structural foam deck and drawers
- Center frame and legs
- Cast aluminum handles
- Wheel axle components
- Custom mounting brackets and stampings
- Plus an assortment of product accessories
The best options for manufacturing these sub-components had not been determined. However, Jake strongly believed that the line should be 100% made in the USA.
DECKED hired a high profile automotive engineering firm to design the system and recommend production processes for the various components.
It was then up to DECKED to select the manufacturing process and the targeted supplier.
Experience and industry contacts made Miles Products stand out.
Decked full-sized truck system showing the numerous parts & components
Innovative design creates storage compartment inside foot structure
Structural foam molded support foot provides heavy-duty strength
Solutions
Launching a new product is challenging in its own right. Doubly so when you’re required to design, engineer and manufacture the product and then develop the marketing channels all from scratch.
Miles Products provided numerous manufacturing solutions, ideas and options for DECKED to consider making the job of supplier selection a more simple task. This allowed the DECKED team to focus their time and efforts on other tasks.
- Miles Products’ longtime partners at 20/20 Custom Molded Plastics are one of America’s leading structural foam molding facilities.
- We offered DECKED a complete service from product and tool design, through production, fulfillment and unmatched customer service.
- Miles Products, 20/20 and the DECKED Engineers worked hand in hand on Design For Manufacturability solutions.
- A seamless collaboration process provided valuable design feedback and assistance.
- A simple, honest and worry-free buying experience is a key part of our offering.
The process proved ideal as well.
- Structural foam molding was perfectly suited for producing the very durable, large-sized yet lightweight components required.
- Technologies such as multi-nozzle molding allowed molding of multiple parts simultaneously, saving on production costs.
- Other benefits of low-pressure molding such as the use of aluminum tools provided further savings.
- Contract manufacturing expertise by 20/20.
Deep manufacturing experience and capabilities.
Along with the main large structural foam components, Miles Products provided manufacturing sources for many of the other product accessories and components.
These included:
- Plastic Injection Molding (product components such as containers, covers & dividers)
- Decorative Metal Stampings
- Die-cast Metal Handles
- Cold Headed Axles and Tie Downs
Together, the various teams worked closely to develop a system that allowed DECKED to meet their required costs and performance goals.
Results
Today DECKED is a leading provider of pickup truck and work van accessories with dealers and distribution in every state of the union. Their customers include contractors both large and small, utility companies, farmers, ranchers and folks who use their vehicles for all sorts of recreational pursuits. DECKED provides products designed for custom installation on most models sold in the USA.
Together with 20/20 Custom Molded Plastics, we remain a trusted partner for DECKED providing molded thermoplastics manufacturing, assembly, distribution services and more.
Fair open dialog on the best course of action to meet customer requirements.
Years of experience in manufacturing excellence; knowledge and know how to meet the tough challenges.
Bring your challenges over to Miles Products, Inc.
Contact us today.
Call 216-533-1410 • Send E-mail