Modernize Aging Electrical Infrastructure Without Shutting Down Production
From undocumented 1980s panels to Industry 4.0-ready systems, unbiased engineering that brings your brownfield facility into the digital era.
Design Systems, Inc. provides high-fidelity electrical engineering services that bridge the gap between heavy-duty power infrastructure and sophisticated digital logic. Whether you are expanding a brownfield automotive plant or commissioning a greenfield parcel-handling hub, we provide the technical depth to handle both the physical wire (Power) and the logical code (Controls).
We don’t just design systems; we ensure they are safe, documented, and ready for the data demands of Industry 4.0.
The Cost of the "Industry 4.0 Gap" in Aging Facilities.
Many North American facilities operate on "tribal knowledge"—legacy systems maintained by memory rather than accurate documentation. As you push for higher throughput and digital transparency, these "islands of automation" become liabilities.
At DSI, we recognize that "as-built" discrepancies aren't just paperwork errors; they are significant financial and safety risks that prevent you from scaling.
Adding modern robotics or high-speed sorters to 1980s-era power panels often creates harmonic distortion and thermal risks that lead to unexplained, costly downtime.
Troubleshooting becomes a nearly impossible task when legacy PLC code lacks internal comments or documentation and the original system designers are no longer with the organization.
Undocumented facility changes made over several decades often result in "regulatory drift," leaving you vulnerable to failed NFPA 70E or NEC audits and significant insurance exposure.
Machines that run efficiently in isolation but fail to report OEE data to your MES create persistent data silos that leave your leadership blind to true floor-wide performance.
Comprehensive Electrical Infrastructure & Control Logic
Design Systems, Inc. engineers industrial electrical systems that integrate high-voltage power distribution with low-voltage control architectures. Our approach ensures that your electrical foundation is robust enough to support advanced Operational Technology (OT) while maintaining strict adherence to North American safety standards. We serve as the vital link between the facility's raw power and the IT department’s data requirements.
The DSI Approach - Unbiased & Vendor-Agnostic
We are an "Engineer's Engineer." Because we do not manufacture hardware or sell proprietary components, our recommendations remain entirely vendor-agnostic.
Whether your facility standardizes on Rockwell Automation/Allen-Bradley, Siemens, Mitsubishi, or Schneider Electric, our engineers focus on the best technical fit for your cycle time and budget, preventing expensive vendor lock-in and ensuring long-term maintainability.
Electrical Engineering Capabilities
Load Analysis & Power Quality
We perform comprehensive system audits to evaluate demand and stability. Our team specializes in the mitigation of harmonics in non-linear networks, ensuring that the proliferation of Variable Frequency Drives (VFDs) and high-efficiency motors doesn't compromise your overall power quality or trip sensitive upstream protection.
Lighting & Ventilation Controls
We move beyond "installing fixtures" to focus on worker safety and operational efficiency. Our team performs detailed photometric analysis and integrates ventilation VFDs into central monitoring systems, ensuring compliance with environmental standards while slashing energy overhead.
Field Wiring & As-Built Documentation
The "Red-Line" process is our specialty. We update your outdated schematics to reflect current facility reality, providing the "defensibility" required for safety audits and future-proofing your next expansion project.
PLC Programming & HMI Design
Our programmers utilize structured text and ladder logic to create intuitive Human-Machine Interfaces (HMI). Our goal is to reduce operator error through ergonomic screen design and simplify troubleshooting with clear, commented, and standardized code.
Network Architecture (Industrial Ethernet)
We design robust industrial networks—including EtherNet/IP and PROFINET—capable of handling the massive sensor density of modern parcel handling and automated warehousing without latency or packet loss.
Virtual Commissioning
Using "Digital Twin" technology, we test your control code in a virtual environment before a single wire is pulled. This drastically reduces onsite debugging time and protects your physical hardware from "first-run" accidents.
MES (Manufacturing Execution Systems) Integration
We connect the shop floor to the top floor, ensuring your machines feed real-time production data directly into your corporate ERP/MES layers for actionable OEE reporting.
Andon & RFID Tracking
We implement visual management systems and automated material flow tracking using RFID, eliminating bottlenecks and providing 100% visibility into your facility's product movement.
Why Engineering Directors Choose Design Systems, Inc.
Since 1983, we have leveraged over four decades of empirical data to navigate every major technology cycle, helping us determine precisely which legacy systems are worth upgrading and which require a total overhaul.
Our unique Onsite Field Wiring Checkout process ensures that every "as-built" drawing matches the physical wiring in your panels, providing a rigorous "double check" that eliminates guesswork and verifies system reality.
While modernization of aging facilities is our most frequent engagement, our team has designed electrical systems for everything from greenfield automotive plants to high-speed parcel hubs across North America.
With strategic offices across the United States, Mexico (Queretaro, Saltillo), and Canada (Windsor), we provide the rare ability to standardize electrical specifications across North American borders to ensure your corporate standards are maintained at every site.