Industry 4.0 & Digital Twin
We combine our 40-year heritage in industrial engineering with advanced Industry 4.0 strategies to solve the "Brownfield Reality", integrating your legacy equipment with tomorrow’s technology using vendor-agnostic Digital Twins.
A PROCESS-FIRST APPROACH
Defining the DSI Digital Twin
What is a Manufacturing Digital Twin?
A Digital Twin is a dynamic virtual representation of a physical system, continuously updated with real-time data to mimic the structure, state, and behavior of the factory floor. It's more than a static 3D model; it is a mirror of your operations that allows for predictive maintenance, remote monitoring, and risk-free experimentation.
The Semantic Layer
DSI adds the "brain" to the body by constructing a semantic layer that links your 3D geometry to critical metadata, including maintenance logs, cycle times, energy usage, and vibration analysis. Using ISO 23247 standards, we ensure interoperability so your Digital Twin can query, analyze, and improve system performance.
COMMON BARRIERS
Why Digital Transformations Stall in Manufacturing
You may have a mandate to modernize, but successful transformation requires more than new technology. Manufacturing environments introduce real operational constraints that generic digital solutions often overlook.
Data Silos: ERP, MES, and SCADA systems often operate independently, making it difficult to turn disconnected data into actionable insight.
Brownfield Infrastructure: Legacy equipment, outdated controls, and incomplete documentation require modernization strategies built around the plant you actually have.
Vendor Lock-In: Proprietary platforms can limit flexibility and tie your operation to a single ecosystem. Your technology architecture should support your long-term needs, not restrict them.
OUR APPROACH
Lean Manufacturing Experts
Design Systems, Inc. can be your resource for success
Utilizing Design Systems, Inc.’s 40 years of lean manufacturing expertise, we can develop practical transformation plans. The Industrial Internet of Things (IIoT) is a long-term process and much of the technology is still being developed and standardized.
Project Outcomes
Clear vision of industry 4.0 for each specific client
Agile, incremental approach
Think strategic, implement tactical
ROI with each project
To learn more about Industry 4.0 and Digital Twin, take a look at these resources:
Design Systems, Inc. Digital Twin Roadmap Flyer
Design Systems, Inc. speaks at Automation Alley Tech Takeover January 2020
The 4 Pillars of Digital Maturity
1. 3D Smart Model
We use 3D Laser Scanning (LiDAR) to capture accurate Point Clouds of your existing facility.
1. 3D Smart Model
We convert your captured facility data into intelligent Revit, Navisworks, and AutoCAD models, replacing outdated 2D drawings with a digital foundation that matches the physical floor.
2. Simulation
We use Virtual Commissioning to test and validate “What-If” scenarios before implementation.
2. Simulation
Using Siemens Tecnomatix, AutoMod, or other platforms, we analyze throughput, identify bottlenecks, and validate kinematics without disrupting production.
3. Visualization
We turn complex operational data into intuitive visual heatmaps and real-time OEE dashboards.
3. Visualization
We break down silos by visualizing data streams, giving Plant Managers a clear view of facility health and turning abstract numbers into operational directives.
4. Immersion
We use AR and VR for immersive maintenance training, safety walkthroughs, and knowledge transfer.
4. Immersion
We help bridge the skills gap by transferring critical knowledge from experienced employees to new hires, supporting safer work and reducing downtime.
WHY DSI
The Lean Heritage Advantage
The Lean Heritage Advantage
At Design Systems, Inc., we aren't just coders; we are industrial engineers. While traditional firms may understand the plant floor but lack the IT expertise for IIoT integration, pure software firms may understand the code without understanding manufacturing. DSI sits in the middle.
A Process-First Approach
We refuse to digitize a bad process. Drawing on our Lean Manufacturing heritage and Value Stream Mapping expertise, we optimize your workflow before we apply sensors. This ensures you are scaling efficiency, not waste.
How DSI Delivers
Objective guidance: With no product line to sell, our focus is on finding the best solutions for your business.
Employee empowerment: We encourage active participation from your team, fostering innovation and adoption.
Industry 4.0 & Digital Twin