Design Systems, Inc. was recently tasked with supporting a large international automaker at one of their Venezuelan facilities. More and more automakers are designing flexibility into their plants, allowing them to build several products on multiple platforms within the same site. This can pose daunting challenges for engineering, and DSI is up for the challenge. This particular site needed to introduce an additional process within the paint shop prior to the primer process. This plant, and in particular this paint shop was space constrained and introducing a new coating process into this area needed to be carefully engineered. Design Systems, Inc., working the OEM’s Paint Engineering staff and suppliers, provided the layout engineering and studies to integrate this new process into the system. Looking at cycle / process times, conveyor options, chording studies, volume constraints, ergonomics issues, safety concerns, and strip out requirements, the team designed a flexible system that will allow this plant to meet production and quality requirements now and into the future.