ENGINEERING SERVICES
Driving Innovation + Efficiency in Industrial Solutions
Engineering Services
Driving Innovation + Efficiency in Industrial Solutions
ENGINEERING SERVICES
The PAC Group provides world-class engineering services that empower industries to innovate, optimize processes, and achieve operational excellence.
Our expertise spans manufacturing, automation, robotics, and product development, delivering tailored solutions that drive efficiency and sustainability.
ENGINEERING SERVICES
Driving Innovation + Efficiency in Industrial Solutions
manufacturing + process
Optimizing Production from Planning to Factory Delivery
The PAC Group delivers manufacturing and process engineering solutions that drive efficiency, scalability, and performance. From production planning, holistic factory design, and advanced process simulation to equipment installation, commissioning and decommissioning, and holistic factory design, our teams ensure every element of your manufacturing environment works in perfect sync. Leveraging lean principles, automation expertise, and digital integration—including 3D layout planning and Digital Twin modeling—we help clients build future-ready facilities that are optimized for flow, flexibility, and long-term competitiveness.
Core Capabilities
Production Planning + Manufacturing Engineering
- Manufacturing Engineering: Design and optimization of Greenfield and Brownfield facilities resulting in robust and efficient manufacturing processes, leveraging a range of advanced engineering and simulation tools for optimal results.
- Process Engineering: Advanced Engineering tools and methods to optimize the process planning on conceptual and serial production level. Incorporating strategic global sourcing to deliver benchmark cost efficiencies and sound production planning frameworks.
- Simultaneous Engineering: Seamless collaboration of Product and Process Engineering from the start, ensuring innovative solutions and streamlined manufacturing.
- Conveyance + Automation + Robotics: Implementing smart and relevant transportation, automation, and robotic systems/solutions to streamline operations.
- Operational Excellence: We meticulously develop comprehensive process documentation and implement precise line balancing, guided by Lean benchmarks. Our detailed analysis of process inputs and outputs ensures thorough optimization and the identification of opportunities for enhanced efficiency and resource utilization throughout the production lifestyle.
Equipment Installations + Decommissioning
- End-to-end equipment lifecycle management, from Factory Acceptance Tests, Packaging and Shipping, Installation, Commissioning, Training, Site Acceptance Tests, Start-up, and even controlled decommissioning.
- Equipment Installation: PAC has decades of experience in Equipment Installation. From greenfield to brownfield, the PAC team has delivered in all automotive shops (Stamping, Body Shop, Paint, Assembly), including Powertrain Plants.
- Decommissioning: PAC has a robust process for Plant Decommissioning, as part of the PAC Operating System, with a specific Safety Procedure following all Safety Standards and one overarching goal: To optimize the value of obsolete or surplus Customer facilities and fixed assets, ensuring full protection of Customer intellectual property.
Factory planning + design
- Master Planning + Location Analysis: Value-flow-orientated production for greenfield and brownfield plants, ensuring long-term competitiveness.
- Factory Structure Planning: Delivering a holistic and sustainable approach to implementing ideal solutions, using sound and methodical know-how, benchmarks, and best practices.
- Layout Planning + Engineering: 2D and 3D layouts for production, process, logistics, and plant design – aligned with the Digital Twin and Metaverse approach for seamless integration and future-ready operations.
- Building, Utilities, + Manufacturing Integration: Ensuring seamless operation with our Manufacturing, Building, and Utilities integration service. We provide engineering and management for the interface between process and plant/infrastructure.
ENGINEERING SERVICES
Driving Innovation + Efficiency in Industrial Solutions
Product Engineering
Design for Complex, High-Performance Products
At The PAC Group, our Product Development team drives innovation from the first sketch to full-scale production. With deep expertise in electrical and mechanical systems, high-fidelity 3D modeling, and advanced simulation tools, we support every stage of the product life cycle. Whether it’s refining A-Class surfaces, integrating next-gen sensors, or designing intuitive human-machine interfaces, our cross-functional engineers and studio specialists deliver precision, performance, and user-focused design for today’s most demanding industries.
Product Development
Full-cycle product innovation, from concept to commercialization.
Electrical Engineering
Expertise in Low Voltage + High Voltage systems for industrial applications.
Mechanical Systems Engineering
Designing and optimizing mechanical components for maximum performance.
3D Modeling + FEA Analysis
Utilizing advanced electrical and mechanical simulation techniques for precision engineering.
Automotive Studio Engineering Support
Clay Modeling + Physical Model Development, Virtual Modeling Expertise, Ideation Design + Conceptual Design and User Experience + Interface Design.
- Expertise in ALIAS and ICEM surf for high-quality surface modeling.
- Precision modeling for A-Class surfaces and concept refinement.
- Experience in CATIA and migration to CREO, ensuring data compatibility.
- Optimizing driver and passenger experience through engineering refinements.
- Early-stage concept development using 3D modeling.
- Design, packaging, and integration of sensors and cameras.
- Support for iterative concept refinement and feasibility testing.
- UX Research + Testing: Expertise in designing navigation and driver assistance systems.
- HMI Development: Support for design, testing, and validation of user-friendly interfaces.
- Vehicle Interior: Optimized ergonomics and interface placement for improved experience.
Product development Engineering
Engineering for Innovative, Scalable Product Programs
PAC offers full-service product engineering services, specializing in a variety of programs such as passenger vehicles and components, equipment/ tooling, assist devices/tools, electric and autonomous mobility, commercial, heavy truck and bus programs.
Our flexible services delivery model, comprised of on-and off-site specialists, has made PAC’s Product Development team one of the most attractive solutions in the industry for commodity excellence and cost efficiency.
Electrical Engineering
Low and High Voltage system engineering:
At PAC, we are driving the future of mobility by supporting the development of next-generation electric vehicles for both heavy-duty and passenger platforms. Our mission is to accelerate the electrification of our clients’ product lines by leveraging the most advanced technologies available—improving energy efficiency, addressing environmental challenges, and paving the way for a cleaner, more sustainable future in urban and commercial transportation. PAC’s expert team delivers fully integrated design solutions for electrical systems, specializing in the development of interconnecting devices, cables, and wire harnesses. Our approach supports both top-down and bottom-up design methodologies, enabling flexible, scalable architectures with a clear system hierarchy and functionality.
Mechanical Systems Engineering
At PAC, we specialize in engineering solutions for both heavy-duty and passenger vehicles, delivering high-performance designs that meet the rigorous demands of the automotive industry. Our expertise includes A/B surface modeling of plastic components, combining Class A surfaces for superior aesthetics with Class B surfaces engineered for structural integrity and functional reliability. We produce highly accurate 2D part and assembly drawings, applying advanced GD+T and stack-up analysis to ensure precision fit and manufacturability. Our team also develops robust tooling solutions for manufacturing lines and after-sales service operations, along with optimized sheet metal components across all vehicle systems. To support clear communication and streamlined production, we create detailed technical documentation, including assembly instructions, service manuals, digital animations, and automated reports.
3D Modeling + FEA Analysis
PAC brings decades of experience in 3D modeling and Finite Element Analysis (FEA) to support the evolving needs of hybrid, electric, and autonomous vehicle development. Our team specializes in structural and harmonic simulations, helping clients validate designs, optimize performance, and ensure durability under real-world conditions. We tailor FEA solutions to meet specific customer standards and engineering guidelines, delivering results that align with both product requirements and regulatory expectations. In addition to simulation services, PAC also develops customized training materials, empowering client teams with the tools and knowledge needed to fully integrate FEA into their product development workflows. We utilize advanced simulation techniques for precision engineering.
Vehicle Program Management
At PAC, effective Program Management is at the core of how we deliver value to our clients. Our engineering team is equipped to lead projects through every stage—initiation, planning, delivery, monitoring, control, and closure—ensuring that milestones are met on time, within scope, and to the highest quality standards. We coordinate the development and release of key vehicle components, including 3D and 2D models, schematics, and drawings for low- and high-voltage cables and harnesses, as well as coolant pipeline systems. Our project teams are also supported by in-house expertise in FEA and modal analysis to ensure critical mechanical structures meet performance requirements. By embedding program management best practices into every engagement, PAC empowers clients to streamline development cycles, mitigate risk, and integrate quality seamlessly across all phases of the product life cycle.
Software Engineering
Custom Software + Digital Tools for Smarter Operations
At PAC we provide world-class Software Engineering and Product Development Services tailored to your business needs.
Our expert teams specialize in Engineering Operations, Quality Assurance, Sustaining Development, and New Product and Tools Development.
- Engineering Operations – Optimized infrastructure, DevOps, and CI/CD methodologies.
- QA + Testing – Comprehensive automated and manual testing strategies.
- Sustaining Development – Maintenance, security, and performance enhancement of existing systems.
- New Product + Tools Development – Innovative software solutions, automation, and AI/ML integrations.
Software engineering services pillars
ENGINEERING OPERATIONS
Infrastructure management and operational excellence through systematic engineering practices and robust DevOps methodology.
qa + testing
Comprehensive quality assurance and testing services, ensuring reliable, high-performance software delivery.
sustaining development
Ongoing maintenance, optimization, and enhancement of existing systems and applications.
New Product
+ tools development
Creation of innovative solutions and custom tools to drive technological advancement and efficiency.
Automation + Robotics
Smart Automation, Scalable Integration, Proven Results
The PAC Group’s Automation + Robotics division delivers high-performance solutions through expert program management, hands-on client support, and cutting-edge technologies. We specialize in overseeing complex automation installations—often at the alpha or beta stage—ensuring seamless integration and rapid scalability.
From technical documentation and process refinement to advanced dock automation (RDE) and sustainable packaging systems (MSP), our team empowers clients to improve throughput, reduce waste, and future-proof their operations.
Program management
Overseeing complex automation installations of solutions that are often in the alpha and beta stages of development.
Client Support
Developing technical documentation used in the installation of automation equipment and providing feedback for continuous improvement and solutioning.
RDE (Robotic Development Engineering)
Delivering leading edge dock automation and robotic installations to better throughput efficiencies.
MSP (Mechatronic Sustainable Packaging)
Producing state of the art packaging solution installations, resulting in reduced packaging waste and improved trailer utilization.
WHY PAC GROUP?
When it comes to complex engineering challenges, clients choose PAC for our proven expertise, global perspective, and future-ready approach. We don’t believe in one-size-fits-all—we deliver customized solutions tailored to your industry, your operations, and your goals.
With a strong foundation in regulatory compliance, cutting-edge technology, and sustainability-first engineering, we help our clients innovate with confidence, operate efficiently, and build with lasting impact. Here’s what sets PAC apart.
Global Compliance Expertise
Supporting clients across automotive, logistics, energy, and advanced manufacturing sectors.
Technology-Driven
Leveraging the latest advancements in automation, AI, and digital twin technology, together with robust, proven, and economic solutions.
Customized Solutions
Tailored strategies to meet the unique demands of your industry.
Sustainability-Focused
Integrating energy-efficient and environmentally responsible engineering practices.
Client Success Stories
Automotive Manufacturer
The PAC Group optimized assembly line automation, reducing production time by 20%.
Logistics Leader
We implemented robotic warehouse systems, increasing order fulfillment rates by 30%.
energy sector
We designed high-voltage energy storage solutions, enabling sustainable power integration.
Product Development
The PAC team implemented an integrated design solution for Electrical Engineering Low Voltage and High Voltage, improving on project development delivery timing and quality.
Equipment Installations + Decommissioning
Recently PAC led the decommissioning process of all plants in a major OEM in Brazil, with zero accidents.
Project Examples
CKD plant – Product Integration
Integrating a new product in Paint Shop and GA Shop during production, The PAC Group planned, engineered, designed, and delivered all required tooling and equipment on a Turnkey basis.
major India-based automotive manufacturer with global EV ambitions
Plant retool and process balancing from a Ford product to a mixed EV/ICE production of local product.
Product Development
Broad experience on smart drawings development, establishing data connection between files (2D Drawings and Electrical Schematics) and leading to full control of Harness BOMs.
engineering services leaders
Product Development + Software Engineering
Henrique Costardi
Vice President | Product + Software Services
Liam Frazier
Director | Software Engineering Services
Ricardo Vegini
Director | Program Management Services
Automation + Robotics
Guira Barretto
Director of Program Management
David Dangerfield
Director of Launch Planning
Manufacturing Engineering Services
Phil Johnston PE
Project Executive | Advisor
