Advanced Automation Engineering for Industrial Operations.

Downtime Visibility

Understand why lines stop and identify recurring production losses before they compound.

Surface the root cause of every line stoppage. BC Automation correlates PLC state changes, operator actions, and alarm sequences into a clear downtime timeline — so your team spends less time guessing and more time fixing.

40% Unplanned downtime reduction | Under 2 min Mean time to root cause

Setpoint Intelligence

Track operator adjustments and correlate them to production performance and quality outcomes.

Every manual setpoint change is a data point. We capture, timestamp, and correlate operator interventions with product quality and output — revealing which adjustments help, which hurt, and which can be automated away.

22% First-pass quality improvement | 100% Operator actions captured

Alarm Reduction

Identify nuisance alarms and prioritize critical events so operators respond to what matters.

Most alarm floods are caused by a small number of recurring, low-priority events. We analyze your alarm history, identify chattering and nuisance alarms, and build a rationalized alarm philosophy — dramatically reducing alarm fatigue.

60% Nuisance alarm reduction | 3x Faster critical event response

Legacy System Modernization

Connect older PLC and HMI infrastructure into modern dashboards and analytics platforms.

You don't need to rip and replace. We bridge your existing Allen-Bradley, Siemens, and legacy SCADA assets into modern analytics environments — preserving your investment while unlocking data that was previously stranded.

0 Production interruptions during cutover | 5x Faster data access vs. legacy

Production Optimization

Reveal bottlenecks, inefficiencies, and hidden process variation across every line.

Hidden throughput is waiting in your existing process. Our MIP layer correlates cycle times, shift patterns, machine states, and quality data to identify exactly where capacity is being lost — and quantifies the recovery opportunity.

12% OEE improvement, first 90 days | $600K+ Annual savings (client example)

Energy & Utility Visibility

Monitor compressed air, power usage, thermal systems, and utility performance in real time.

Energy is the hidden cost in most plants. We instrument compressed air, power draw, steam, and thermal systems — then correlate consumption to production output so you know exactly where energy is being wasted per unit produced.

18% Energy cost per unit produced | Real-time Utility consumption visibility

Field / Sensors (L0 – L1)

Plant technicians & maintenance teams

Converts raw sensor data into reliable predictive maintenance insights.

MIP ingests data from PLCs, edge devices, and field instrumentation to surface anomalies before failures occur — giving your technicians clear, prioritised alerts instead of raw noise.

60% Mean time to detect | 40% Unplanned stoppages

Controls / SCADA (L2)

Automation engineers & control system managers

Unifies fragmented PLC and real-time data for faster troubleshooting.

A single contextual view across all control assets eliminates screen-switching and guesswork. Engineers resolve alarms 3x faster when every signal is correlated and timestamped.

3x Alarm resolution time | 100+ Data sources unified

MIP Intelligence Layer (Hub)

Digital transformation & OpEx leaders

Delivers process Twins, predictive analytics, and actionable intelligence.

The intelligence core that connects everything — Process Twins model your operation in real time, ReflexIQ™ detects and responds autonomously, and OperationalIQ™ surfaces decisions before they become problems.

Real-time Decision latency | Under 90 days ROI timeline

MES / Operations (L3)

Production planners & quality managers

Synchronizes work orders, scheduling, and quality systems in real time.

MIP closes the loop between shop-floor execution and planning systems — work orders update automatically, quality deviations trigger immediate containment, and schedule changes propagate instantly.

28% Schedule adherence | 65% Quality escapes

Cloud / Enterprise (L4 – L5)

Executives, supply chain & BI leaders

Bridges OT to IT for trusted boardroom-level insights.

Live OT data flows securely into SAP, Oracle, Power BI, and other enterprise platforms — giving executives accurate, audit-ready KPIs without waiting for end-of-shift reports.

Live vs. 8 hrs Report latency | 12+ ERP systems supported

Control System Modernization

Midwestern Food Manufacturer Cuts Downtime by 40%

Legacy Allen-Bradley PLC migration to modern PAC with edge connectivity — zero production interruption.

40% downtime reduction

Manufacturing Intelligence Platform

Chemical Plant Unlocks $12M in Annual Yield Gains

MIP deployment unifying control data, MES, and ERP into a single intelligence layer.

$12M annual yield improvement

AI Copilots

Automotive Supplier Reduces Quality Escapes by 65%

OperationalIQ™ and TrustLabel™ copilots deployed across 3 facilities in 90 days.

65% fewer quality escapes

How do we begin working with BC Automation?

We start with a no-cost Discovery Call to understand your current systems, pain points, and operational goals. From there, our engineers conduct a detailed site assessment and deliver a scoped engagement plan — typically within two weeks. There are no obligations until you approve the scope.

Can you migrate our legacy PLC systems without shutting down production?

Yes. Zero-downtime migration is a core competency. We use a phased parallel-run methodology — your existing systems stay live while the new architecture is commissioned and validated alongside them. Switchover happens in a planned, controlled window, typically under four hours.

What makes your AI Copilots different from generic AI tools?

Our copilots — Vizionary™, ReflexIQ™, OperationalIQ™, and TrustLabel™ — are purpose-built for industrial environments. They are deterministic and hallucination-free, meaning they rely on your actual process data and pre-validated logic rather than generative guessing. Every recommendation is traceable, auditable, and ISA/IEC-compliant.

Do your solutions integrate with our existing MES, ERP, and SCADA systems?

Yes. Our Manufacturing Intelligence Platform (MIP) is designed as a unifying layer across L0–L5 of the Purdue Model. We have pre-built connectors for SAP, Oracle, Ignition, OSIsoft PI, Rockwell FactoryTalk, Siemens, and more. Custom integrations are scoped per engagement.

How do you handle cybersecurity across OT and IT environments?

We align to ISA-99 / IEC 62443 standards and implement zero-trust network segmentation between OT and IT zones. Our SPA™ architecture provides quantum-resilient connectivity with immutable process lineage, ensuring your operational data is protected at rest and in transit. We also conduct threat modeling as part of every engagement.

How long does a typical engagement take, and when do we see ROI?

Engagement timelines vary by scope: a focused PLC migration can complete in 6–12 weeks, while a full MIP deployment across multiple facilities typically runs 3–6 months. Most clients see measurable ROI — in the form of reduced downtime, improved yield, or lower labor costs — within the first 90 days of go-live.

What does ongoing support look like after a project is delivered?

We offer tiered managed service agreements (MSAs) covering 24/7 monitoring, remote diagnostics, firmware and software patching, and on-site response SLAs. Our average response time for critical incidents is under two hours. Many clients also retain us on a fractional basis for continuous improvement initiatives.

What industries and platforms does your team specialize in?

Our engineers hold certifications across Allen-Bradley / Rockwell, Siemens, DeltaV, and Emerson platforms. We primarily serve food & beverage, pharmaceuticals, chemicals, automotive, and discrete manufacturing. Every project is staffed with engineers who have hands-on experience in your specific vertical.