Warehouse & Distribution
Validate throughput, capacity, and automation before implementation.
WAREHOUSE & DISTRIBUTION
Engineer the System Before You Invest
Warehouse and distribution systems become more difficult to optimize as operational complexity increases.
DSI uses discrete event simulation and decades of material handling experience to design and validate warehouse and distribution systems, from manual picking to ASRS integration.
We connect facility planning, material flow, and technology into one engineered system designed to improve throughput, use space efficiently, and support changing operational demands.
The Cost of Inefficiency
Confronting "The Wall" and the Labor Crisis
For many Tier 1 Suppliers and Logistics leaders, the greatest threat to profitability isn't the competition, it’s the physical limitations of their own facility. You may be facing "The Wall," a phenomenon where floor space is maximized, yet throughput remains stagnant because vertical cubic strategy has been ignored.
This bottleneck is compounded by a shrinking skilled labor market. The inability to scale throughput simply by adding headcount is a reality for facilities across North America.
When you rely on legacy data silos, spreadsheets, and "tribal knowledge" rather than integrated WMS/WCS environments, you risk Operational Expenditure (OPEX) drift and missed deliveries.
Design Systems, Inc. moves you away from reactive fire-fighting and toward predictive, engineered control.
WAREHOUSE OPTIMIZATION
Holistic Warehouse Engineering & Optimization
Process Simulation & Validation
DSI engineers use advanced Discrete Event Simulation (DES) to model operations 3–5 years into the future. By testing real-world variability and peak demand, we validate capital expenditures (CAPEX) before equipment is ordered.
Facility Layout & Space Utilization
Hidden capacity exists in almost every brownfield site. DSI uses 3D modeling to identify vertical density and cubic utilization opportunities that 2D floor plans can miss, helping delay costly construction or expansion.
Automation & Technology Integration
From ASRS and AGVs to complex conveyance systems, DSI provides vendor-agnostic integration. We align Material Handling Equipment (MHE) with process and inventory requirements so automation solves the right operational problem.
Engineering Capabilities & Methodologies
Slotting Optimization
We utilize data-centric algorithms to analyze SKU velocity and physical dimensions.
By placing high-velocity items in the "Golden Zone," we significantly reduce travel time and pick-path latency, directly impacting your bottom line.
Inventory Management Systems
DSI bridges the gap between physical hardware and software logic.
We help you migrate from manual tracking to sophisticated IMS environments that utilize RFID and IoT tracking for real-time visibility.
Material Handling Equipment Selection
Our team provides unbiased, engineering-grade assessments of hardware options. From Robotics and Sortation to Palletizing systems, we select equipment based on your specific throughput requirements, not vendor partnerships.
Greenfield vs. Brownfield
We deploy distinct strategies for different site types. For Greenfield projects, we design for unencumbered flow. For Brownfield sites, we specialize in retrofitting operating plants, implementing Just-in-Sequence (JIS) changes and upgrades without causing operational downtime.
Certainty in Execution
Virtual Commissioning We debug the system digitally before you buy the hardware. By emulating the control logic against a virtual twin of your system, we resolve code and sequence errors early. This drastically reduces on-site ramp-up time and eliminates the "hope it works" phase of commissioning.
North American Footprint With offices in Farmington Hills (USA), Windsor (Canada), and Queretaro and Saltillo (Mexico), DSI offers seamless cross-border engineering support. We understand the nuances of supply chain continuity across the USMCA region, ensuring your standards are maintained regardless of location.
Independence We sell engineering solutions, not hardware. We advocate for the process, not the vendor. This independence allows us to sit on your side of the table, protecting your interests and ensuring that every dollar of CAPEX is directed toward a validated operational improvement.
See it in Action
Warehouse Design and Facility Layout Simulation
See how DSI uses simulation to visualize warehouse layouts, evaluate material flow, and validate facility design before implementation.
Warehouse & Distribution