CASE STUDY – Detroit Manufacturing Systems LLC (DMS) – Detroit

CASE STUDY – Detroit Manufacturing Systems LLC (DMS) – Detroit, MI
INTRODUCTION:
The client end user, Detroit Manufacturing Systems LLC (DMS), needed a new installation for its
startup vehicle component manufacturing facility in Detroit, MI. DMS contracted Larry Brinker Jr., vice
president of L.S. Brinker Co. (LSB) of Detroit, MI, to construct a new compressor room, compressed air
network, information technology studio and various commercial and industrial components.
Darryl Kukla from Air Technologies of Livonia, MI, was the project’s sales engineer.
The facility needed to be up and operational within a four-week time period. The compressed air system
replaced the previous black steel compressed air piping.
PROJECT SPECIFICS/ISSUES:
To install a complete, balanced, efficient, corrosion-free, leak-free compressed air distribution piping
network while DMS got its new vehicle component manufacturing facility operational and functional
within a four-week period. As DMS expanded its operations, LSB was required to relocate various
compressed air lines throughout the plant with no advance notice.
• Size of facility – 450,000-square-foot facility
• Cost of project – $250,000 over seven installation
phases
• Current piping system – black iron piping existed,
but DMS had no existing compressed air piping
system.
• Installation pipe diameter/length:
• 100mm/2,780 feet
• 63mm/1,400 feet
• 40mm/ 680 feet
• 25mm/1,060 feet
• Compressor – Two (2) 50HP Atlas Copco GA37
Screw Compressors
• Flow rate: 229 CFM
• Service pressure: 125 PSI
• Distributor – Air Technologies; Livonia, Mich.
BACKGROUND:
Detroit Manufacturing Systems: Detroit Manufacturing Systems (DMS) develops state-of-the-art
automotive interior systems. Utilizing the latest technology, DMS assembles and manufactures
injection molded interior trim components for global automotive brands with a commitment to
quality and efficiency.
ENGINEERING YOUR SUCCESS.
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CASE STUDY – Detroit Manufacturing Systems LLC (DMS) – Detroit, MI
DMS was founded in June 2012 as a joint venture with Rush Group Ltd. and French auto supplier
Faurecia Interior Systems. Majority partner, Rush Group, is 100% owned by President/CEO, Andra
Rush, who is a Native American, Woman-Owned Business entrepreneur who has been supplying the
automotive industry since 1984.
Faurecia Group is based in Nanterre, France and is the sixth largest automotive supplier in the world.
Faurecia Interior Systems is the number one vehicle
interiors supplier worldwide, supplying instrument panels,
center consoles, cockpits, door panels, door modules and
acoustic systems.
The new joint venture, located in the Gateway Industrial
Center in Detroit, is the largest Native American owned
automotive supplier in North America.
L.S. Brinker Co.: L.S. Brinker Company (LSB) is a fullservice general contracting firm established in 1993 to
provide construction and redevelopment services. LSB
specializes in renovations and expansions for industrial
facilities, commercial properties and mixed-use office
buildings. Self-perform capabilities include drywall, metal framing and studs, glass and glazing,
aluminum entrances, compressed air equipment and piping, electrical systems, and flooring. LSB hires
subcontractors within all trade categories. As a direct result of in-house self-perform capabilities, LSB
successfully maximizes efficiency, achieves schedule optimization and realizes project cost savings.
Issues/Concerns – Because DMS had no existing system, there were no compatibility issues. However,
LSB faced difficult deadlines throughout the project due to DMS being a startup.
CHOOSING TRANSAIR:
DMS specifically requested a Transair piping installation because its joint venture partner, Faurecia North
America, uses Parker-Transair as a standard of practice. DMS made the initial design of the system, but
Air Technologies and LSB helped the company redesign the system to maximize long-term operational
maintenance and scalability, as well as efficiency, thus saving money.
RESULTS:
The ease of installing Transair piping, as well as its availability, increased labor-hour efficiency and
helped LSB meet their scheduled deadlines. As DMS increased its operations, LSB was on call for
relocating lines throughout the plant with no advance notice. The lightweight piping was easy to move
and reinstall, making it logistically easier for LSB to maintain a staging area in one section of the plant
and move the material to installation areas without using excessive manpower or requiring forklifts.
DMS maintained operations throughout the various stages of the expansion. The new system met the
company’s requirements for cleanliness, aesthetics and efficiency. It also cut installation labor costs by 60%.
ENGINEERING YOUR SUCCESS.
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CASE STUDY – Detroit Manufacturing Systems LLC (DMS) – Detroit, MI
CONCLUSION:
In the short term, using Transair piping allowed DMS to get the plant up and running within a small
target window of time. LSB helped get the facility operational 60% faster than if they had used traditional
black piping. The lightweight material, ability to add drops when needed, and the overall ease-of-use
were beneficial for the project, mainly because of continuous assembly line relocations. With traditional
black pipe, LSB would have had to locate the nearest tee (typically at the end of a 20-foot length of pipe)
and pipe back to the actual point of use.
In the long term, Transair is guaranteed not to leak or corrode for 10 years. The overall design minimizes
condensate contamination, which would lead to corrosion and rust particulate in a traditional black pipe
system. Even if water were to enter the Transair system at any point, there would be no risk of corrosion.
The design also incorporated two existing compressors in the facility. This reduced DMS initial costs
by eliminating the need to purchase a third compressor. The refined design provided a balanced
compressed air loop and storage capacities.
ENGINEERING YOUR SUCCESS.
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