What's New At Design Systems, Inc.
Design Systems awarded material flow project for a leading Battery Manufacturer.
The overall plant Material Flow Analysis includes the flow of lithium ion raw materials and components from the inbound truck docks to the internal material storage and staging areas, through the proposed facility, to the point of use. The Material Flow Analysis will continue with the completed lithium ion components and subassemblies from the end of their processes, through the packaging and shipping of those completed components. Utilizing lean production techniques, Design Systems team will perform a truck dock analysis, production material storage analysis, material handling analysis, and an indirect labor analysis.
Design Systems Canada Ltd. (DSC) was awarded and has completed phase I of a process layout development project for a Salt mining/processing plant.
Phase I involved the development of a current/reliable layout to be used for locating the new proposed grading equipment. Phase II will involve locating the new process, validating the process flow requirements and be used in the development of demolition and new installation Bid Specifications.
Design Systems, Inc. works with major call center in the US.
People don't normally associate call center operations with the manufacturing environment. However, Design Systems, Inc. has been awarded a contract doing just that. We will examine and optimize operations using discrete event AutoMod simulation as the primary analysis tool. We will look at the practices, methodologies and procedures using simulation to improve throughput, reduce wait times and increase utilization of the center's direct labor. This project illustrates another example of how lean manufacturing techniques apply to all industries.
Design Systems Canada Ltd. (DSC) has been awarded 2 contracts to assist a local distiller/bottling company
with the replacement of a new energy efficient absorber. By replacing the older, less efficient absorber the operation will gain in additional electricity generating capability as well as reduce their costs to produce steam that drives the generators. As part of this replacement project, DSC is assisting with soliciting and obtaining energy reduction grants to help offset the cost of the change. This work comes as they are completing the 1st phase of program management of a plant wide energy management system and lean manufacturing process.
Design Systems is under contract to provide engineering services to develop conveyor modules utilizing 3-D/emulation software Demo3D™
The modules can then be used to create a dynamic model to visualize flow and provide a unique perspective of the overall system operation. Additionally, Demo3D™ can, ultimately, provide PLC controls testing for off line logic and HMI testing.
Design Systems, Inc. is working with RCM Engineering, a Brazilian engineering and project management firm located near Sao Paulo
RCM has extensive experience with automotive, heavy equipment and electronic manufacturers in Brazil. In conjunction with Design Systems’ Turnkey Manufacturing Engineering and Integration services which include: conveyors, material handling, controls, paint processing equipment, FIS / AVI in all manufacturing industries and RCM providing local fabrication and installation we can support the tremendous manufacturing industry potential in Brazil and South America.
Design Systems, Inc. working closely with a large tire manufacturer for their new facility in Brazil
DSI is developing the detailed bid specifications for the complex material handling systems. With a variety of conveyance methods and complex build sequence requirements the controls design is critical in making the flow and throughput requirements. With several years experience in the tire manufacturing industry our conveyor and controls groups have the experience to handle the most complex systems and bring the project in on time.
Design Systems, Inc. is providing engineering services to a large Aerospace firm
Services include development of a new manufacturing layout for a new product line. With this new layout development we are providing Lean Manufacturing techniques to optimize the building footprint size and cycle times for the operations. Through this process we are evaluating conveyance methods, material handling methods, material storage requirements, material flow, work station evaluations and budget estimates for the project. We are also providing a full Simulation model of the facility to validate the complex build sequence and product mix DSI is looking forward to a long relationship with our new customer and applying many services from our Conveyor Group, Controls Group, Process Group and Manufacturing Engineering Group.
Design Systems, Inc. awarded project within heavy-truck manufacturing facility
Throughout the many model introductions, capacity increases, Lean manufacturing programs, and process rearrangements, the facility drawings were out of date and not consistent with any accepted CAD standard. Design Systems' task initially was to completely update the facility drawings to an accurate as-built status reflecting the actual conditions on the shop floor. The field engineering team gathered on-site and began the arduous effort of field checking the site, including conveyors, process equipment, utilities such as water, gas and air mains, and electrical runs / drops. The team took the next step and identified all the material locations, both line side use and staging areas. This effort will provide an easy transition into potential new product planning and Program Management activities using accurate and up-to-date as-built AutoCAD drawings.
Design Systems completes "Design and Build" of Paint and Elpo process fixtures
for two major U.S. automotive manufactures. These fixtures are used to support the production of spare parts used for in-shop repairs and dealer replacement parts. DSI was responsible for gathering / downloading the latest available product math data, complete design, fabrication and installation of the new part fixtures into the Paint Shop facilities. DSI also developed a complete set of 3-Dimentional "As-Built" shop detail drawings for each part fixture for customer use. DSI can provide services such as; design engineering, detail engineering, carrier design, conveyor application engineering, conveyor evaluations, conveyor health assessments, impact analysis, part buck design, production aid design, prop rod design, as-built and as-installed drawings, chain pull, chain analysis, structural support steel design, load analysis, load trolley analysis, clearance studies, reverse engineering, structural clamp design, bid package engineering, etc...Design Systems to provide the engineering and design
of a "Brownfield" automotive paint shop renovation for new vehicle production in North America. The paint shop will re-utilize much of the existing facility process equipment and facilities and will incorporate the latest available technology with respect to energy conservation and reduction of "Greenhouse" gas emissions. The paint shop will have the production capacity of 160,000 units per year.
Design Systems awarded contract - design and engineering
for installation of equipment and systems at a "Brownfield" facility that will produce high efficiency engines for both electric drive and conventional drive automobiles. The facility will have the capacity to produce 400 engines per day with the flexibility to increase production to 1,200 engines per day.
Design Systems Canada provides engineering services to major distillery
DSC was contracted by a major distillery to complete a solar feasibility study to utilize solar thermal heat as a supplementary heating source for their facility makeup air system. Design Systems, Inc. is providing integration solutions with renewable energy to the food & beverage industry.Design Systems Canada provides engineering services to a major automotive supplier to expand their existing tank farm operation
DSC provided the engineering design, bid package and field installation support for the installation of a new diesel fuel tank farm and dispensing system for a major automotive supplier. Design allowed for TSSA Fuel Safety variances in addition to containment engineering and distribution design which entailed over 2,000 feet of mechanical piping.DSI Conveyor/Mechanical Engineering Group successfully completes project for large European auto manufacturer
This company had been dealing with a significant amount of chain surge on a production conveyor which not only created system downtime but also induced a significant amount of unnecessary wear on the system. After trying to solve this issue with their own resources and also working with other companies to no avail, DSI was contracted to do a complete evaluation and conveyor health assessment. Upon our completion of this assessment, which included; conveyor chain pull analysis, numerous take-up readings, and drive and system component capacity related calculations, DSI engineered a simple cost-effective solution. This conveyor design solution was incorporated using the customer's internal resources and the issue was resolved. DSI can also help you resolve your conveyor problems, conveyor faults, conveyor failures, conveyor breakdowns, etc... like this example or assist you by providing some of our other services such as; design engineering, detail engineering, carrier design, conveyor application engineering, conveyor evaluations, conveyor health assessments, impact analysis, part buck design, production aid design, prop rod design, as-built and as-installed drawings, chain pull, chain analysis, structural support steel design, load analysis, load trolley analysis, clearance studies, reverse engineering, structural clamp design, bid package engineering, etc...DSC provides engineering services to major distillery and bottling operation
DSC was contracted by a major distillery and bottling operation to study and develop an alternate process fluid storage and piping delivery system. Since this original release we have received orders for studies and bid package development for spill containment, plant ventilation, energy reduction projects and are further working with them on the implementation of Solar hot water systems to pre heat or replace their current steam applications.DSC continues to expand its PSR, Pre-Start Heath and Safety Review – a regulatory requirement in Ontario, Canada, and TSSA application, approval and review, engineering services
As part of our engineering services to our clients, DSC can provide across the board assistance to ensure that our Clients and their suppliers, comply with and meet, the provincial requirements for PSR and for TSSA inspections and approvals. Call 519-944-8807 for specific application and service requirements.DSI recently awarded a Turnkey program for Quality Systems in Mexico
Design Systems, Inc. has recently been awarded a Turnkey contract to provide Engineering, Project Management, Equipment, and Installation for an assembly plant in Mexico. The DSI engineering team will be required to provide Electrical Control Panel Design, PLC programming, Panelview programming and on-site system commissioning. The system installation will help the plant better achieve its quality goals, and will involve state-of-the-art integration of plant floor systems to upper level control systems.DSI Awarded Electric Vehicle Powertrain Manufacturing Plant Contract
Design Systems, Inc. has recently been awarded a contract to prepare engineered installation packages for a new Powertrain program for a major domestic manufacturer. The engineering will include requirements for equipment mechanical installation, utilities tie-ins, mist collection, coolant supply and return and ancillary support equipment for a complete integrated facility. The plant will utilize existing refurbished equipment, new equipment and equipment relocated from remote facilities. Scheduled production start for this program is early 2010.DSI Awarded Axle Manufacturing Company Contract
Design Systems, Inc. has recently been awarded a contract with an Axle Manufacturing Company to provide Program Management and Turnkey Equipment Installation services for their new Greenfield Axle Manufacturing Plant. The scope of work for this project includes; layout development and maintenance, development and management of the master timing schedule, detail engineering for facilities, field management of construction trades, and complete installation of all process equipment including fire suppression systems and process ventilation. The plant is scheduled to launch in early 2010.Put Our Simuation Experience To Work For You!
Design Systems, Inc. offers Simulation services with an experienced staff dedicated to solving any bottleneck issues and increasing your throughput numbers with our detailed simulation software packages. We use a variety of software packages including AutoMod, Witness, Quest, Simul8 and Demo3D.Design Systems, Inc. is an authorized AutoMod re-seller. Let us help you increase your production numbers.
Design Systems, Inc. Tops Quality Charts!
Design Systems, Inc. takes pride in providing quality Engineering services to our customers. Each of our groups, Mechanical and Conveyor, Electrical and Controls, Manufacturing and Industrial Engineering, Paint and Process Engineering, Simulation and Emulation and Structural, continually focus on quality and continuous improvement in our Engineering service offerings. Over the past two years we have maintained over a 95% quality rating from our customers for Overall Program Management and Project Execution. As these difficult times continue for all of the industries, we will continue to provide cost-effective solutions at high quality standards for our customers.Design Systems, Inc. continues its tradition of one-stop turnkey engineering
DSI has been tasked with the design, fabrication, and installation of a research & development conveyor system to validate a new process. DSI has taken this project from the early conceptual design stage to reality in the field. The R&D test is being conducted to simulate the concept through a phosphate / E-coat system. The intent of this test is to identify the viability of the conveyor concept as it is processed through its load and unload stations and to test the stability through vertical and horizontal curves. The test will show functionality to load / unload the skid in a cost-savings effort.
New Addition to our Health Assessment Expertise
In our continuing effort to provide the highest level of specialized services to each client, Design Systems now has a full time Tribologist on staff. Tribology is a key part of our ability, as a company, to provide meaningful and accurate system “health assessments” for each of our clients. In these economic times, we all need to make equipment last longer and do more – a Design Systems Heath Assessment will help you do this with your systems and equipment.
Tribology – “the branch of engineering that deals with the interaction of surfaces in relative motion (as in bearings or gears): their design and friction and wear and lubrication” - wordnet.princeton.edu/perl/webwn
Bob Meyers, Assistant Group Manager - Electrical & Controls to present paper at EVER Conference
The paper Solar Energy Application in a US Automotive Plant Feasibility Study ( in conjunction with Lawrence Technological University, Professor of Mechanical Engineering , Daw R. Alwerfailli, Ph. D.) is devoted to analyze the procedures necessary to adapt solar power systems to industrial manufacturing facilities. While solar power has been in existence since the 1950s, its popularity is growing due to the negative impact carbon emissions impose on the environment as a result of coal generated electricity. Wide use of solar in industrial applications will grow this renewable to help reduce the overall costs by volume, and lead to affordability for residential use. An automotive components plant was used to provide a realistic approach of the process needed to evaluate the feasibility of integrating solar power.
View the paper: 
Solar Energy Application In A US Automotive Plant Feasability Study
Design Systems, Inc. is up to "Greener Things"
Leadership in Energy and Environmental Design – LEED. DSI's Sustainable Initiatives service offering has reached a new milestone with Troy Shinavier achieving LEED accreditation - Leadership in Energy and Environmental Design. With Mr. Shinaviers's status as a LEED Accredited Professional, the US Green Building Council (USGBC) will add Design Systems, Inc. to a local and national registry with LEED Accredited Professionals on staff.LEED accreditation through the US Green Building Council allows Mr. Sinavier to consult with clients from all industries looking to understand and implement sustainable practices in their facilities. LEED for existing buildings focuses on the following design disciplines:
- Sustainable Sites
- Water Efficiency
- Energy and Atmosphere
- Material and Resources
- Indoor Environmental Quality
- Innovations in Upgrades
As a full service engineering provider, DSI supports the Sustainable Initiative platform with solid engineering resources to meet the ever-changing needs our clients.
Design Systems offers new service - "Green Initiatives" !
In this ever-changing engineering environment, there are new "Green Initiatives" that are driving the facilities and process design. We at DSI have recognized the need to participate in this "Green Movement" and will be aligning ourselves as a firm that can educate, engineer, and certify our client in the implementation of these sustainable practices.
Design Systems has been awarded an engineering contract for a major engine manufacturer in India.
Design Systems (USA) is working with Design Systems Engineering Services in Bangalore (India) to engineer the tool and equipment drawings and specifications for their complete installation in India. Drawing and bid package preparation for Engineering will jointly be performed by both offices.Design Systems is starting a project in Thailand for a major engine and powertrain supplier.
Installation bid package engineering work will be done by both Design Systems headquarters in Farmington Hills, MI and Design Systems Engineering Services in Bangalore, India.Design Systems Inc has been awarded a Simulation Engineering contract by major steel manufacturer.
Design Systems Inc will assist our customer to optimize their BOP (Basic Oxygen Process) by developing a simulation to accurately depict the entire process from the blast furnace through the continuous casting line. The resulting model will comprehend all system variables and predict results from varying process inputs.
"JOB WELL DONE..." Design Systems, Inc. receives congratulations from one of our core customers in the tire manufacturing business.
DSI provided Project Management services for a launch at one of their key facilities. Services included: overall program coordination, project scheduling, layout development and coordination, conveyor controls development, coordination and integration support for the project.Design Systems Completes a New Paint Shop Program.
DSI provided Program Management services for this two year assignment. Services included all aspects of a new Paint Shop Project: project management, paint booths, paint ovens, conveyors, work decks/platforms, system controls, simulation of the complete facility, emulation of some key areas, ASRS system, sludge system, paint circulation systems, RTO systems and IT systems.Design Systems, Inc. Awarded a Major Equipment Installation Engineering and Program Management job.
Our customer is a leading manufacturer of Heavy-duty trucks. Working on this greenfield site in Mexico has allowed DSI to tap into our growing engineering resources in that region. Areas of focus include reviewing all mechanical and electrical design drawings, developing and managing a detailed project schedule, preparation of bid packages, assisting in bid award, managing installation and coordinating all open issues, manage start-up activities, conduct final buyoffs and inspections, ensure delivery of all as built drawing packages and manuals.Design Systems providing on site overseas engineering services to major US Automotive firm.
Our customer required assistance for the support of a greenfield automotive paint facility in St. Petersburg, Russia. DSI provided project coordination for the execution of daily site activities, chemical cleaning and filling, spare parts and maintenance manuals, scheduling, start-up and launch activities for major systems within the paint facility. The results of these efforts will produce a world class facility through the efforts of an international team bringing together lessons learned, lean manufacturing concepts, and benchmarking from around the world.Design Systems providing Japanese Transplant automotive manufacturer energy savings.
Our customer required assistance for the support and development of energy saving programs within their existing automotive paint facility. DSI provided the concepts and detailed bid packages for the implementation of air supply house controls and cascading ventilation systems. Working with the customer, Design Systems developed the concepts, provided all energy calculations, provided cost estimates, calculated the return on investment (ROI), developed all necessary drawings, provided written scope of work, attended pre-bid meetings and verified the final return on investment (ROI). Because of the designs, additional cascading ventilation concepts will be investigated throughout the facility.Design Systems providing Large International Manufacturing facility energy savings.
Design Systems was tasked to identify energy savings opportunities within our customer's facility. The goal of this task was to reduce overall energy consumption in the manufacturing facility by 20%. These energy savings opportunities identified through the reduction of city water, wastewater, natural gas and electricity accounted for an overall annual savings of 40% with a return on investment as low as 18 months. With a team effort from the facility engineer, the optimization of the customer's process and facility with respect to steam boilers, solar energy, lighting equipment and solvent recovery were optimized.Design Systems providing ventilation and utility designs for major automotive powertrain facilities.
Our customer has required assistance for the engineering and project management assistance for multiple greenfield and brownfield powertrain facilities throughout the world. Our scope for this service included indentifying all utility requirements, bid packages for equipment installation, evaluations of existing facilities, accurate sizing of all utility piping, design of the required ventilation and mist collection systems, bid packages for all utility piping and ventilation systems, program management of installation contractors and field assistance. Throughout these programs, we have found further customer benefits to include vendor coordination, scheduling management, electrical load distribution and coordination of field activities.Design Systems completes automotive powertrain facility technical specification.
The bid package was done for a large automotive powertrain manufacturer and included; machining line equipment locations, utility layouts, utility sizing for machining coolant supply and return systems, coolant filter modification requirements, ductwork sizing for mist collection systems, electrical power distribution requirements and communication interface cabling plants.Design Systems material handling engineering provides significant cost savings.
Being selected to engineer a comprehensive material handling plan to rearrange over sixty (60) bridge crane systems for a large automotive manufacturer in an existing engine powertrain manufacturing facility. This material handling engineering will be conducted using cost saving and value engineering principles and will include the reuse of all existing plant assets to be maintained in cooperation with the plant skilled forces performing the work using and opportunity-based schedule. The result will be a significant cost savings for the customer in addition to supporting full utilization of the plant's skilled trades workforce.Design Systems assists local food manufacturer.
Our customer is investigating the potential of building / renovating a manufacturing facility for production purposes. Our scope includes: Feasibility Study, providing our customer accurate sizing and budget cost estimates for this proposed facility. We will provide a macro-level process layout of the facility, determine Utility requirements, and provide an overall evaluation of the building as it relates to supporting our customers' current and future needs.Continuing this project would potentially include: developing detailed bid packages for equipment and installation, preparing detailed project schedule and finalizing an equipment list. Further in the process we could assist this customer with on-site management and vendor coordination, permit process, ongoing schedule management, on-site system commissioning and training, detailed controls engineering and PLC programming, coordination of all "As-Built" documentation.