Engineering-Backed Facility Optimization That Actually Fits Your Building
We bridge the gap between process optimization and the physical reality of your building's structural and electrical capacity.
Your layout consultant says you can add 20% capacity. Your structural engineer says the roof won't support it. Your controls integrator says both plans won't work with your existing PLC architecture. Sound familiar?
Overcoming Operational Complexity and Capacity Constraints.
For Engineering Directors and VPs of Operations, the margin for error is non-existent. You are tasked with increasing throughput and integrating advanced Industry 4.0 technologies, often within the constraints of legacy facilities. We understand the specific paralysis caused by:
Squeezing increased capacity out of existing brownfield square footage without disrupting current production or compromising safety.
Navigating the high-stakes risk of tooling mismatches and equipment failures during aggressive New Product Introduction (NPI) timelines where launch dates are immovable.
Overcoming the inefficiency and finger-pointing that occurs when managing disjointed vendors for process design, structural support, and controls integration.
Mitigating the hidden costs of operational downtime caused by poorly integrated legacy systems and new automation layers.
The Cost of Inefficiency
Every bottleneck in your conveyor system and every unoptimized localized buffer translates directly to reduced Overall Equipment Effectiveness (OEE). In high-volume manufacturing and logistics, poor space utilization isn't just an annoyance—it is a continuous drain on profitability that delays ROI on capital expenditures.
The DSI Approach - From Simulation to Physical 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.
Helping You Find the Solutions You Need
Our engineering process begins by identifying your setbacks and clarifying your end goals.
Our consultants use their experience and extensive expertise to determine how to most effectively solve your problems.
In addition to analyzing your industrial processes and operations, we also analyze:
Tooling & Equipment
Structural Support
Painting & Coating Strategies
Mechanics
Layouts of Facilities
Electrical Systems
Conveyances
Control Panels, Systems, & Designs
Building Utility Systems
Looking at all of these processes allows us to see what changes are needed in order to make your operations, workflows, and processes run as smoothly as possible.
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
We maximize square footage utilization through rigorous Material Flow Analysis and Spaghetti Diagrams. From optimizing AGV/AMR routing to seamless Warehouse Management System (WMS) integration, we ensure material moves logically and efficiently from dock to dock.
Tooling, Equipment & Conveyance
DSI specializes in the selection and design of complex material handling systems. Our capabilities include Power & Free conveyors, Skillet systems, and AS/RS implementation. We also provide ergonomic tooling design and comprehensive strategies for Paint Shops and Coating Application Systems to ensure finish quality meets OEM standards.
Infrastructure Engineering (The Physical Reality)
Process optimization fails if the building cannot support it. We perform Structural Support Analysis for overhead conveyance, evaluate Building Utility Systems (Air, Water, Power), and conduct Electrical Load Analysis and Control Panel Design. We validate the facility's physical ability to handle the new process loads.
Digital Transformation & Virtual Commissioning
We digitize your physical assets to drive smarter decisions. utilizing 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 Directors Partner with Design Systems, Inc.
Our goal is to help you increase the efficiency of your current processes and resolve issues you may have in your workflows or operations.
We have over 40 years of experience and have successfully completed thousands of projects. Design Systems, Inc. is consistently recognized as a Top 50 Design Firm in the manufacturing sector, and a Top 50 Program Management Firm by ENR.
In a market saturated with niche consultants, DSI offers the scale, stability, and technical diversity required for enterprise-level success.
We eliminate the gap between the process engineer and the structural engineer by handling the mechanical, electrical, and structural scopes in-house to reduce change orders.
Our seamless project execution across the US, Canada (Windsor), and Mexico (Saltillo, Queretaro) makes us the ideal partner for nearshoring initiatives and cross-border standardization.
With over 250 professionals and a history dating back to 1983, we have the bandwidth and financial stability to manage massive capital projects that smaller firms cannot support.
We are consistently recognized as a Top 50 Design Firm (Manufacturing) and Top 50 Program Management Firm by ENR, validating our industry authority.