Total Container Management Solution Provider

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DSI has grown steadily over the past 23 years into one of the industry’s premier manufacturing process engineering companies. From our perspective, the world is indeed getting smaller, as is evident by the demand for our people and services around the world. Although there are many countries with a wealth of graduating engineers in various fields, the manufacturing engineering skills and experience we have developed here in the Motor City are sought not only by automobile manufacturers but also a variety of manufacturing companies around the world.

I credit our longevity and success to maintaining our focus on providing quality work and continually developing new services to support the needs of our customers. We have maintained a core group of long term dedicated employees with many of us having over 20 years of service with DSI. Our experienced staff welcomes the opportunity to support you with your manufacturing engineering or project integration needs.

I want to thank all of you – our customers – for your support and encourage you to give me a call if you have any questions on the many engineering services we provide.

Sincerely,
Dan Birchmeier
Director of Sales and Marketing

What’s Inside:
Some of DSI’s services to consider for your facility improvement projects:

  • Total Container Management Solution Provider

Maximizing Productivity by Design

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What’s Inside:
Some of DSI’s services to consider for your facility improvement projects:

  • Hot Equipment Can Chill Your Bottom Line
  • Vehicle Quality Assurance is a Matter of Nuts and Bolts
  • Working Safely is the Smart Way to Work
  • Manufacturing Systems, Prevention is Cheaper than the Cure
  • Baggage Handling Systems that let you Grow

Maximizing Productivity by Design

Engineering Safe and Efficient Work Environments

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<h3>Powered Industrial Vehicle Safety</h3>

In a perfect system, workers and machines would come together to create a safe and efficient process. As you and I know however, the reality of most manufacturing facilities is far from this idyllic setting. Design Systems is a leader in meeting the challenges of productivity and worker safety within the beehive of a manufacturing complex. Whether you call them hi-lows, forklifts, or lift trucks, these Powered Industrial Vehicles and their interaction with pedestrians within the facility create opportunities for accidents that can be prevented with the proper design and material handling methods. Design Systems will develop a thorough solution for your unique facility: to protect your staff, meet the daily production requirements, and to help your bottom line by reducing expensive worker compensation costs. Contact a representative today to set up your free site analysis.

<h3>Implementing World Class Manufacturing Techniques</h3>

Whether it’s the Toyota Production System, World Class Manufacturing, Lean Production Systems, Synchronous Manufacturing or any of the myriad of other terms; they can mean different things to different people. Throw in some Japanese terms – Muri (overburden), Mura (unevenness), Muda (waste elimination), Kaizen (improve) and Kanban (billboard) and we start to confuse what started out as a straightforward concept. World Class Manufacturing is about common sense and empowerment: common sense in the approach to manufacture more efficiently, to produce what the customer wants, when they want it and empowerment of people closest to the process to effect changes.

Common sense and empowerment may sound simple in principle, but are much more difficult to achieve in practice. To truly be considered “World Class” in manufacturing and reap its benefits, a complete cultural change across an entire organizational structure is required from the top down. Design Systems, Inc. is helping our customers get there. With our thorough understanding of the principles involved, the nuances of execution and our experience in team building, we can help facilitate and enable your efforts. Whether you are just starting down the road to World Class Manufacturing or want to get to the next level, let us show you how we can help make your journey a success.

Photovoltaic Technology

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PV technology converts sunlight directly into electricity throughout the day, allowing you to produce your own electricity with no noise, air pollution, or moving parts. The basic building block is the PV cell, which is connected to other cells to create larger units called modules. Typically, modules are attached as panels onto your existing roof or are designed directly into the roof so they act as both a part of the roof or shingles and a solar module at the same time.

A PV system includes a collection of PV modules that is usually connected to the utility grid. Systems must be connected to the utility grid to be eligible for the cash incentive offered by the resident state. The PV modules produce direct current (DC) electricity, which the system then converts to alternating current (AC) electricity so it can be used to power your lights, appliances, and other home electrical needs.

The applications of Solar Power Energy are extremely broad. The Solar Power Energy can be used at home, commercial, farms, schools, hospitals, general manufacturing industry, automotive industry, government buildings, sports events, etc.

Design Systems Photovoltaic Technology Services:

  • Design a unique system to meet your performance requirements.
  • Conduct site surveys and identify potential PV applications.
  • Identify the basic configurations and components required for PV system installations.
  • Obtain solar radiation data and apply this information in estimating the performance of PV systems.
  • Identify electrical and mechanical design issues associated with PV system installations.
  • Successfully and safely complete PV system installations

“BOTTOM-LINE” RESULTS:

  • Infinite Energy Resource
  • Reduce Operating Expense
  • Reduce dependency on a centrally controlled power grid and energy infrastructure
  • Reduce Pollution

Wind Technology

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Wind Technology

Wind Technology converts the kinetic energy of the wind into electricity. Given the multidisciplinary nature of wind farm projects, the integration of all components is essential to the success of the project. DSI can design and integrate the wind farm components, including the generator step-up specification into a cost effective solution for your specific project. The DSI team can manage the overall project including: design, schedule, cost evaluation and risk management.

DSI offers an advanced control system to continually adjust the blade pitch angle in the turbine to enable it to achieve optimum rotational speed and maximum lift-to-drag at each wind speed. This “variable speed” operation maximizes the ability of the turbine to remain at the highest level of efficiency resulting in greater annual energy production yield as compared with machines operating at constant speed. Additionally, while constant speed rotors must be designed to deflect high wind gust loads, the variable speed control system enables the loads from the gust to be absorbed and converted to electric power. Generator torque is controlled through the frequency converter. This control strategy allows the turbine rotor to over-speed operation in strong, gusty winds thereby reducing torque loads in the drivetrain. The wind turbine converts the extra energy in wind gust to electric power.

Design Systems Wind Technology Services:

  • Design a unique system to meet your performance requirements.
  • Conduct site surveys and identify potential applications.
  • Identify the basic configurations and components required for system installations.
  • Obtain wind data and apply this information in estimating the performance of wind systems.
  • Identify electrical and mechanical design issues associated with wind system installations.

“BOTTOM-LINE” RESULTS:

  • Infinite Energy Resource
  • Reduce Operating Expense
  • Reduce dependency on a centrally controlled power grid and energy infrastructure
  • Reduce Pollution

Sustainable Energy Solutions

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Energy and Utility Management

DSI has the experience in Energy & Utility Management throughout industrial and commercial applications to bring value added solutions and Energy Reduction to your facility through:

  • Design and Engineering
  • Specification Generation
  • Implementation and Program Management
  • Commissioning and Launch
  • Total Turn Key Solutions

Utility Related Cost Containment

  • Chilled and Hot Water
  • Compressed Air
  • Electrical
  • Natural Gas
  • Potable and Process Water
  • Steam
  • HVAC

“BOTTOM-LINE” RESULTS:

  • Reduces Energy Consumption
  • Improve Energy Efficiency
  • Increase Productivity
  • Enhances “ROI”
  • Saves Money

Sustainable Initiatives – LEED Sustainable Initiatives

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LEED Process & Certification Initiatives

Environmental preservation and improvement has transcended from a grassroots social movement to mainstream America. DSI is working with its clients to transition them into this “greener”, more sustainable environment and to reduce their building’s negative impact on the environment, while helping to improve the bottom line.

Energy saving and efficient design is nothing new for DSI. For over 25 Years, DSI has been designing efficiency into every project. With LEED (Leadership in Energy and Environmental Design) Accredited Professional(s), DSI will measure and document the gains for its client, as well as assisting with the implementation of LEED processes. As members of the USGBC (United States Green Building Council), DSI is working with existing and new clients to improve their bottom line through:

  • Energy Savings
  • Process Improvement
  • Employee Retention
  • Forward Thinking Design

No matter the motivation – social or economic, DSI will work with you in the design, implementation and LEED certification of Green and Sustainable Processes.

“Bottom Line” Results:

  • Increases Good Will and Brand Equity
  • Increases Workforce Productivity
  • Reduces Energy Consumption
  • Increases Property Values
  • Increases Employee Health & Well Being
  • Increases Employers Ability to Retain Talent

“Strategic Alliance” Support Team – Midwest Paint Shop Program

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PROJECT

Midwest Paint Shop Program

CUSTOMER

General Motors Corporation

Objectives

Develop a “Strategic Alliance” Support Team for GMVO Paint Engineering Group’s procurement of a new paint shop. Team responsibilities included program administration, scheduling activities, financial control, document control, program safety support and training coordination.

Description

GMVO Paint Engineering Group planned to procure a new paint shop facility, including all building and process requirements, from a single full-service contractor, rather than using multiple vendors for engineering, site construction, building construction, equipment installation, etc. The initial screening of contractors for capability of performance was the responsibility of GMVO Paint Engineering.

GMVO Paint Engineering needed a knowledgeable engineering/construction resource during the team engineering, site construction and facility activation stages.

“Bottom Line” Results

A Design Systems “Strategic Alliance” Support Team Concept was developed for the new GMVO Paint Shop that permitted the client flexibility of resource management without incurring additional fixed program costs. The concept included:

  • Engineering resources provided by the OSI team working parallel engineering studies with the full-service contractor engineering team. These parallel studies permitted the client to examine numerous alternatives offline without impacting the primary scheduling timeframe.
  • Alternate layout configurations being developed by the OSI Team based on site topography. This effort resulted in the client being able to reduce site preparation by approximately 30,000 cubic yards of fill material and 1400 lineal feet of retaining wall.

The DSI Team was configured to provide both full time and part time personnel as required to complete engineering and construction tasks in a timely manner and at minimal cost. The team consisted of five permanent members: Program Administrator, Administrative Assistant, Scheduler, Financial Controller and Document Controller. Six part time members were assigned to Miscellaneous Paint Process, MSQ Document Control, Electrical Controls, Contract Cost Management, Information Systems and Administrative Launch Assistance.

Vehicle Assembly – Underbody Robotic Sub-Assembly

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PROJECT

Underbody Robotic Sub-assembly

CUSTOMER

General Motors Corporation

Objectives

  1. Evaluate and prove the systems’ ability to meet throughput objectives of 90 JPH “gross” and 77 JPH “average yield.”
  2. Identify any deficiencies (bottlenecks) in cell flow as well as potential improvements to the cell design.
  3. Define the effects of downtime, part shortages and operator efficiency.

Description

A base model was developed for each of the subassembly cells under study. The base model simulation was run without the effects of downtime to verify that objective #1 was achieved and that input parameters were correct. Based on a random approach, downtime effects were applied to the model, and changes in the system behavior were recorded. This allowed the identification of system bottlenecks from statistical data. “What-if” scenarios were then performed on the simulation model to determine how the effects of downtime, material shortages and operator overcycles can be offset, thereby improving throughput.

“Bottom Line” Results

System Throughput: 78.5 JPH Base model
Downtime Applied: 73.9 JPH
Early and Late Breaks: 64.9 JPH
Part Shortages On: 59.3 JPH
Quality Issues On: 47.4 JPH


Station 13 identified as the system bottleneck. Part 14957 shortage significantly affected throughput.

Eliminating material shortages associated with part 14957 –> resulted in 52.1 JPH


Replacing Station 13 fixed conveyor with an accumulating conveyor –> resulted in 52.8 JPH


Improving Station 13 and Robot 11 cycle time to 40 sec –> resulted in 59.5 JPH


Eliminating early and late breaks –> resulted In (;1.4 JPH


Eliminating quality issue problems and resulting delays –> resulted in 84.2 JPH

Vehicle Assembly – Floor Pan Build System

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PROJECT

Floor Pan Build System

CUSTOMER

General Motors Corporation

Objectives

  1. Analyze the system and identify potential bottlenecks.
  2. Evaluate the systems’ throughput at 100% capacity, with allowances for probable unscheduled downtime.
  3. Evaluate “what-if” scenarios to improve system performance to a gross of 115 JPH.

Description

Floor Pan Build System consisting of material handling and shuttle robots, welding robots, operators, turntable stations, and part sub-assemblies.

General Methodology

A baseline simulation model was developed reflecting the current operating conditions of the Floor Pan Build System. An analysis verified that the system’s operationallogic and cycle times could support the measured gross rate, taking into consideration process interaction, but without the effects of downtime. A net rate analysis was performed employing downtime data derived from actual observations. The data was analyzed, filtered and incorporated into the model when evaluating the impact of downtime on the system. Experimentation with respect to cycle time reductions was performed with the objective of achieving a target gross throughput of 115 JPH

“Bottom Line” Results

BASE MODEL:

Gross Throughput –> 99.6 JPH
Net Throughput –> 85.0 JPH


AFTER CYCLE TIME CHANGES:

Gross Throughput –> 114.6 JPH
Net Throughput –> 97.5 JPH


Recommendations on ways to reduce cycle times in “arious al8Bs went offered, and included in the final report. For example, regstrling shuttle robots 10 and 19, the suggestion was made to eliminate the shuttle robots’ staging movements, thus eliminating redundant parts handling and reducing cycle times.

Material Handling Systems – Preform AGV Delivery System

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PROJECT

PreformAGV Delivery System

CUSTOMER

Western Container Corporation/Coca Cola

Objectives

  1. Evaluate and test the AGV systems’ throughput capability under anticipated operating conditions.
  2. Verify that eight AGVs will maintain throughput demands.
  3. Compare the effects of one, two or three home stations (AGV park empty waiting for next pick-up task).

Description

Automated Guided Vehicle (AGV) pick-up from 12 additional preform machines and delivery to automated bin unload station.

“Bottom Line” Results

AGY system can service 24 preform machines without ever impacting preform machine throughput (blocked by full containers).

One home station (empty AGY parking) provides the greatest flexibility and quickest response time to waiting machines.

System would meet production requirements with as little as five AGYs, indicating excess system capacity.