Transforming custom power solution manufacturing
For manufacturers producing highly customized products, managing customization with manual design processes is a key challenge. As products become more complex, the potential for errors, delays, and inefficiencies increases. DriveWorks design automation, 3D product configurator, and CPQ solutions enable manufacturers to speed up design timelines and deliver custom products more efficiently. Trystar implemented DriveWorks to automate engineering processes, reduce errors, and significantly improve customer response times.
The challenge
Trystar is a leading provider of power solutions across North America. Their customers come from a wide range of industries, including data centers, utilities, healthcare, commercial facilities, and entertainment venues.
Their products range from configured solutions to fully bespoke electrical systems, and as their business grew, engineering and sales teams struggled to keep pace with demand for customized products. Their challenges included:
- Increasing engineering workloads and resource constraints
- Design standards that were inconsistently documented or applied
- Errors and rework caused by rushed processes
- Long back-and-forth discussions between sales, engineering, and customers
- Incomplete or incompatible product specifications from sales teams
The solution
To address these challenges, Trystar implemented DriveWorks to automate the configuration, design, documentation, and quoting process for generator docking stations. Trystar captured its product rules and engineering expertise within DriveWorks. Sales teams can now use a guided configuration interface that leads them through the product specification process and prevents invalid combinations and missing information.
As users make selections, DriveWorks automatically:
- Applies engineering rules and design standards
- Validates configurations
- Generates 3D CAD models
- Produces 2D drawings
- Creates complete customer submittal packages
- Collects supporting documentation, schematics, and component cut sheets
- Generates manufacturing information and BOMs
The benefits
The implementation of DriveWorks delivered several measurable benefits for Trystar:
1. 85% of projects bypass engineering
Approximately 85% of projects now bypass engineering entirely, enabling engineers to focus on innovation and high-value custom work.
2. Over 30,000 engineering hours saved
Within the first year of using DriveWorks, they processed more than 3,000 product configurations. With an average of 10 hours saved per build, Trystar estimates it saved approximately 30,000 engineering hours.
3. 90% reduction in errors and rework
By embedding engineering standards and product logic directly into the system, Trystar significantly improved consistency and accuracy. As a result of preventing configuration mistakes before they reach engineering and consistently applying design standards, rework and errors have decreased by 90%
4. Faster customer response times
Before using DriveWorks, generating customer submittal packages could take a few days or even weeks, depending on engineering workload and sales preparation time. Now, a complete package can be generated automatically in 10 to 15 minutes, giving customers the information they need much faster.
5. Increased revenue and growth
As lead times have decreased and customer response times have improved, sales volumes and revenue have increased significantly.
Our sales have gone up because the lead times have gone down. Customers are happy. So we just have more projects rolling in.
Jared Smith, Staff Mechanical Engineer at Trystar
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