Industrial Engineering
We bridge the gap between process optimization and the physical reality of your facility’s structural, electrical, and controls infrastructure.
THE DSI APPROACH
From Simulation to Commissioning
Design Systems, Inc. provides a single-source solution for industrial engineering. We integrate data analysis with physical installation support to ensure your facility performs as designed.
We conduct deep-dive on-site audits to identify bottlenecks and validate your "as-built" conditions against "as-designed" drawings to ensure accuracy from day one.
Our team leverages virtual commissioning and flow analysis to validate concepts and predict throughput issues before any capital is spent.
We provide detailed mechanical, electrical, and structural engineering to manage the physical installation and commissioning of your new process.
We execute the final ramp-up support to ensure the line hits rate immediately upon launch, rather than months down the road.
OPERATIONAL CHALLENGES
Solving Complex Capacity Constraints
For Engineering Directors and VPs of Operations, you are tasked with increasing throughput and integrating Industry 4.0 technologies, often within legacy facilities.
Increasing capacity within existing brownfield square footage without disrupting production or compromising safety.
Navigating tooling mismatches and equipment failures during aggressive New Product Introduction (NPI) timelines.
Managing disjointed vendors for process design, structural support, and controls integration.
Mitigating downtime caused by poorly integrated legacy systems and new automation.
The Cost of Inefficiency
Every bottleneck and unoptimized buffer translates to reduced Overall Equipment Effectiveness (OEE). Poor space utilization can delay ROI on capital expenditures.
ENGINEERING CAPABILITIES
Helping You Find the Solutions You Need
Our engineering process begins by identifying your setbacks and clarifying your end goals.
Our consultants combine experience across tooling and equipment, electrical systems, conveyance, controls, utilities, structural support, mechanics, facility layouts, and coating strategies to determine the right approach for your operation.
By looking at these systems together, we can identify the changes needed to help your operations, workflows, and processes run more efficiently.
Comprehensive Industrial Engineering Capabilities
Our expertise spans the full lifecycle of the manufacturing plant. We do not just optimize the flow; we engineer the structure that holds it and the power that drives it.
Facility Layout & Flow Optimization
Optimize space, material flow, and facility performance.
Facility Layout & Flow Optimization
We maximize square footage through material flow analysis, optimizing AGV/AMR routing and WMS integration to ensure efficient material movement.
Tooling, Equipment & Conveyance
DSI specializes in the selection and design of complex material handling systems.
Tooling, Equipment & Conveyance
DSI selects and designs material handling systems, including Power & Free conveyors, Skillet systems, AS/RS, ergonomic tooling, and Paint Shop solutions that meet OEM standards.
Infrastructure Engineering
We validate the facility's physical ability to handle the new process loads.
Infrastructure Engineering
We perform Structural Support Analysis for overhead conveyance, evaluate Building Utility Systems (Air, Water, Power), and conduct Electrical Load Analysis and Control Panel Design.
Digital Transformation
Validate decisions virtually before changes reach the plant floor.
Digital Transformation
We utilize 3D Laser Scanning (Point Cloud to BIM) to create accurate Digital Twins, and Discrete Event Simulation to test "what-if" scenarios, ensuring your upgrade works on the first day of production.
Why Engineering Leaders Partner with DSI
Our goal is to help manufacturers improve the efficiency of their current processes and resolve challenges across their operations.
With more than 40 years of experience and thousands of completed projects, Design Systems, Inc. brings the scale, stability, and multidisciplinary expertise required for complex manufacturing programs.
Single-source engineering — Mechanical, electrical, structural, and process engineering capabilities help reduce gaps between disciplines and change orders.
North American execution — Teams across the U.S., Canada (Windsor), and Mexico (Saltillo, Queretaro) support nearshoring initiatives and cross-border standardization.
Scale to support complex programs — More than 250 professionals provide the bandwidth and financial stability to manage projects beyond the capacity of smaller firms.
Recognized industry experience — DSI has been recognized by ENR among leading design and program management firms.
Industrial Engineering