In the world of manufacturing, having products made and assembled entirely at one site offers several key advantages. When Cabot’s envisioned their EasyDeck™ Applicator—an innovative tool designed to make deck maintenance effortless—they turned to W&S Plastics, a trusted advanced manufacturer with a proven track record.

A Strong Partnership

Built on an existing relationship forged during the pandemic and a history of collaborations, the partnership between Cabot’s and W&S Plastics was a natural fit. Cabot’s needed more than just a supplier; they required a partner capable of managing the complexities of the project, including manufacturing and delivering a fully assembled, retail-ready product in time for the busy summer season.

W&S Plastics’ ability to streamline production timelines through efficient tooling processes, combined with their supply chain expertise and proficiency in building complex assemblies, ensured the success of the EasyDeck™ Applicator project.

A Unique Venture

The EasyDeck™ Applicator project was managed entirely under one roof at W&S Plastics’ Sydney facility. This complete box build approach ensured every step of production—from sourcing components to moulding plastic parts, assembling the product, and packing it for retail—was handled internally.

The result? A fully assembled applicator that left the W&S Plastics factory retail-ready, heading straight to distribution centres and store shelves. By eliminating the need for third-party involvement, the process was more efficient and adaptable to any required changes. It also significantly reduced transportation requirements, minimising costs and lowering the overall carbon footprint.

Cutting-Edge Equipment, Quality Control and Expertise

Producing the EasyDeck™ Applicator also required advanced machinery, skilled expertise, and rigorous quality control. Every detail was carefully considered, with key processes including:

  • All moulding was completed on-site using various machine sizes and materials.
  • Components like clamp jigs underwent additional processing to meet exact specifications.
  • Six specialised jigs were designed and fabricated to ensure precision at every stage:
    • Assembly jigs for accuracy and efficiency.
    • Go/no-go gauges for verifying component lengths and sub-assemblies.
    • Pressure and flow checks to guarantee the integrity of pump assemblies.

These measures ensured the EasyDeck™ Applicator met the highest standards of functionality and durability.

Streamlined Processes

The end-to-end process for the EasyDeck™ Applicator showcased the benefits of W&S Plastics’ approach:

  • Component parts were ordered and inspected for quality.
  • Plastic parts were moulded in-house.
  • Quality control checks were conducted throughout, from goods inwards to final assembly.
  • Components were combined into assemblies within the W&S assembly room.
  • Sub-assemblies were completed, packaged, and made retail-ready.
  • The finished product was delivered directly to distribution centres.

The process was backed by reduced lead times and simplified logistics, resulting in cost savings, all while maintaining strict quality standards. The approach was also flexible and adaptable if design modifications were required.

Local manufacturing also empowered the Cabot’s team to actively engage in the production process, visiting the facility to see their product come to life.

Explore the possibilities with W&S Plastics

This project demonstrates W&S Plastics’ technical expertise, dedication to customer satisfaction and commitment to ensuring Australia’s manufacturing sector is strong.

The full product manufacturing and assembly process offers numerous benefits backed by solid project management, timely communication, and prompt responses.

Customers also have the opportunity to visit W&S Plastic’s premises and witness their products being manufactured, ensuring transparency and confidence in the process. The team also can manage or assist with designing and developing customer concepts.

Get in touch today to discuss your next project via info.wsp1@wsplastics.com.au.

About Cabot’s EasyDeck™

A key feature of Cabot’s EasyDeck™ clean and coat maintenance system is the plastic applicator designed to apply the bottle of decking refresher maintenance coat developed by Cabot’s. By loading this plastic EasyDeck™ Applicator with Cabot’s coating liquid, decking can be coated easily and with no prep required. Find out more here:  https://www.Cabot’ss.com.au/product/Cabot’ss-easydeck-applicator/