This site is protected by reCAPTCHA and the Google Privacy Policy and Terms of Service apply.
Package Handling
DCS’s design and engineering team has more than 40 years of experience creating unique parcel handling systems for diverse customer applications. With installations including semi-automated handling in small city distribution centers and fully automated, integrated hubs with advanced conveyor and sorter equipment, DCS routinely thinks outside the box.
E-Commerce and Multi-Channel Fulfillment
DCS designs and implements end-to-end warehouse automation solutions for e-commerce and multi-channel retailers that address numerous workflow challenges. This includes solutions for receiving, putaway, storage, replenishment, order fulfillment, picking, packing, sortation, and outbound shipping. Our custom integrated warehouse, distribution, and fulfillment systems draw from a deep pool of conventional, semi-automated, and automated material handling technologies.
Various Distribution Applications
Whether an operation is considering the construction of a new distribution or fulfillment center, or a retrofit or expansion of an existing facility, it’s important to create a solution that fits the overarching supply chain strategy. DCS has four decades of experience designing and integrating comprehensive, end-to-end material handling solutions that meet a multitude of operational goals. Whether conventional, semi-automated, or fully automated, DCS can help your organization implement a custom solution that meets its goals while maximizing return on investment (ROI).
Supply Chain Consulting
The DCS Supply Chain Consulting team offers a range of services to help your operations address the challenges it faces. Working in partnership with you, DCS consultants analyze your business data- existing workforce, workflow processes, inventory, order data, operations, and more- to determine a strategy that addresses your unique needs. Whether you need an operations assessment, process improvement recommendations, or distribution design services, DCS consultants will help guide you to the material handling system or operational solution that best meets your current and future needs, as well as your budget.
Customer Support
Keeping your warehouse operations and material handling systems running smoothly and at the peak of productivity are the goals of DCS’ Customer Service Team. By partnering with DCS, your warehouse automation solution is supported from commissioning to end of life. You’ll receive comprehensive in-house training of your personnel, including specialized training of your designated internal system expert. Plus, DCS offers a complete package of spare parts and expert system troubleshooting support from qualified engineers dedicated to your installation.
System Design & Integration
DCS offers a broad range of material handling equipment and automated system design, installation, and integration services for a multitude of projects. These include retrofits, expansions, upgrades, and more. While every project is unique, our system design and execution processes are the same, encompassing meticulous attention to detail, frequent communication, and a dedicated partnership with our clients.
Life Science & Healthcare
Pharmaceutical, healthcare, and life science companies face mounting pressure from evolving regulatory requirements, rising fulfillment costs, and intensifying accuracy demands. In this environment, automation isn’t optional—it’s essential. Designed Conveyor Systems (DCS) helps distributors of these critical products stay compliant and competitive.
Pet Food
Pet food distribution operations are anything but standard. From bulky kibble bags to delicate fish tanks, stock keeping unit (SKU) complexity and fulfillment pressure are always on the rise. Designed Conveyor Systems (DCS) partners with leading pet retailers to design and engineer automation, software, and material handling systems that keep operations agile, accurate, and ready for what’s next.
Home Improvement
When your distribution center handles everything from hammers to hot tubs, operational complexity isn’t a challenge—it’s your daily reality. Home improvement retailers face intense pressure to meet rising consumer expectations across multiple channels—from in-store pickups to last-mile delivery. At Designed Conveyor Systems (DCS), we specialize in engineering material handling and automation solutions that help home improvement distribution centers keep pace, reduce cost, and drive accuracy at scale.
Sporting Goods
Navigating the unique demands of the sporting goods retail industry requires a distribution strategy that’s both agile and precise. From handling seasonal surges to managing a diverse range of products—from bulky equipment to small accessories—your warehouse operations are the key to a seamless customer experience. Our expertise helps sporting goods retailers streamline their distribution warehouses, improving order accuracy, boosting productivity, and ensuring your team can efficiently move products from the receiving dock to the final customer, no matter the season.
Footwear
In the fast-paced world of footwear retail requires a distribution strategy that can handle a vast array of styles, sizes, and seasonal trends with precision and speed. From managing a high volume of SKUs to ensuring accurate order fulfillment and returns processing, your distribution center is the engine that drives customer satisfaction and brand loyalty. Our expertise helps footwear retailers streamline their distribution centers, improving inventory management, accelerating order processing, and ensuring your team can efficiently move products from the receiving dock to the final customer, no matter the season.
Wholesale & Industrial Distribution
Designed Conveyor Systems (DCS) partners with wholesale, industrial, and electronics distributors to design efficient, optimized fulfillment solutions. Every operation DCS designs streamlines end-to-end functional processes—from inbound receiving and putaway to picking, packing, and shipping. Designed Conveyor Systems (DCS) partners with wholesale, industrial, and electronics distributors to design efficient, optimized fulfillment solutions. Every operation DCS designs streamlines end-to-end functional processes—from inbound receiving and putaway to picking, packing, and shipping.
About Us
Designed Conveyor Systems (DCS) has 40 years of experience serving major clients in multiple industries by providing material handling, full-scale warehouse operations, and conveyor design solutions that are custom crafted for their needs. DCS does not sell ready-made conveyor systems but builds relationships that empower collaboration to craft custom warehouse designs together. DCS utilizes consulting, engineering design, project management, installation services, and client support to ensure our customers can keep their promises to deliver on time.
Projects
With more than 40 years of experience providing automated system design, installation, and integration services, DCS has created solutions for companies throughout the United States in a broad range of industries and markets. We’ve completed more than 1500 projects ranging from greenfield facilities with completely new systems to expansions and retrofits of existing operations.
Upcoming Events
Designed Conveyor Systems values building strong relationships with our clients. Join us at our upcoming events to collaborate and discover how we can design a custom warehouse solution tailored to your unique needs.
Keeping Custom Material Handling System Integration Projects on Track in Live Facilities
Keeping Custom Material Handling System Integration Projects on Track in Live Facilities
Custom material handling system integration projects often take place in facilities that must remain fully operational during construction. Balancing the demands of a live workplace with the needs of a complex installation project requires careful planning, strong communication, and close coordination between the customer and the installation team.
I saw this firsthand while spending time at a customer site where our team of material handling systems integrators was constructing a new conveyor line to expand their current operation. With associates still working in the building, the project required additional safety coordination and operational planning to ensure the installation progressed efficiently while maintaining a safe working environment.
At the same time, staying on schedule was critical. As a resource manager supporting the on-site deployment team—while also coordinating contractors and installation activities—I gained several insights that may help facility owners and operators preparing for similar projects. Here are some tips for keeping custom material handling system integration projects on track in live facilities.
Communication Is the Most Important Tool
Frequent communication is essential on every installation project. When construction is happening inside a live facility, however, those conversations become even more important.
Facility operations, safety requirements, and project conditions can change quickly. Increasing the frequency of communication between supplier and customer representatives helps ensure everyone stays aligned and minimizes confusion when adjustments are needed.
Regular discussions also allow both sides to quickly address challenges and identify solutions that keep the project moving forward.
Review On-Site Safety Requirements
Every facility has its own safety policies and operational procedures. Before installation begins—and throughout the project—both the facility operator and the installation team should review these requirements to ensure full compliance.
Safety considerations may include:
- Required personal protective equipment (PPE)
- Equipment operating zones
- Procedures for working near active production or fulfillment areas
- Documentation of personnel working on-site
- Access protocols for entering and exiting the facility
Regularly reviewing these requirements helps ensure everyone understands expectations and avoids unnecessary disruptions.
Establish Clear Responsibility for Safety Oversight
Another important step is determining how safety policies will be monitored and enforced during the installation. For example:
- Will the facility assign someone to oversee compliance in the installation area?
- Will the installation team designate a safety lead?
- How will safety requirements be communicated to new contractors or team members?
Defining these responsibilities early helps prevent misunderstandings and ensures consistent adherence to facility policies.
Plan for Situations Where Workspaces Become Tight
Certain installation tasks—such as installing conveyor sections or reviewing detailed configuration drawings—may require team members to work closely together or within limited space.
Discussing these situations in advance allows both parties to determine the safest and most efficient approach for completing the work. In many cases, minor adjustments to workflow, staging areas, or scheduling can minimize disruption while maintaining productivity.
Prepare for Potential Timeline Adjustments
Installation teams always strive to keep custom material handling system integration projects on schedule. However, working within a live facility can introduce variables that affect timelines. For example:
- Access to certain work areas may be limited during peak operating hours.
- Safety procedures may require additional coordination.
- Operational priorities may occasionally take precedence over installation work.
When these factors arise, open communication allows both parties to address potential delays quickly and make any necessary adjustments to project timelines or staffing levels.
Discuss Supply Chain and Equipment Availability
Custom material handling system integration projects depend on a wide range of components and equipment, and supply chain conditions can sometimes affect delivery timelines.
Maintaining open communication about equipment availability and potential delays helps project teams prepare alternative sourcing options or adjust schedules when necessary. Planning ahead reduces the risk of unexpected slowdowns during installation.
Strong Collaboration Drives Successful Installations
In our recent project, regular communication between the customer and material handling systems integrators played a major role in keeping the project on track. Supervisors increased coordination with the installation crew, reviewing daily priorities and reinforcing facility safety procedures. Team members also supported one another by maintaining safe work practices and keeping shared tools and equipment organized throughout the day.
Ultimately, successful installations depend on collaboration. When both sides work together, communicate clearly, and align expectations, even complex projects within active facilities can move forward smoothly.
Planning a Facility Expansion or Automation Project?
Installing new material handling systems in an operating facility requires thoughtful coordination between engineering, operations, and installation teams.
If you’re planning a facility expansion or automation project, DCS can help evaluate your requirements and develop an installation strategy that minimizes disruption while keeping your project on schedule.
Connect with DCS to learn more about how we support successful system implementations in live and greenfield facilities.
_
Author
Brian Niccum, Manager of Site Management, briann@designedconveyor.com
With 20+ years in the industrial, baggage and material handling industries in both airports and distribution warehouses, Brian has developed and refined an expertise in electro-mechanical conveyance installations. In his career he has worn several hats – from an apprenticeship level to superintendent, and now proudly wears one as our Manager of Site Management. Brian has a love for comedies, sports and more importantly his family and 3 bulldogs. They thoroughly enjoy Disney trips as well as spending time at the beach and in the Smokey Mountains.