Solution › Automation
BEN Engineering delivers end-to-end industrial automation — from field-level control systems and SCADA to enterprise software integration and Industry 4.0 transformation. We help manufacturers and process industries reduce downtime, increase throughput, and achieve full visibility from the shop floor to the boardroom.
Our automation engineers combine deep domain expertise in control systems with modern software integration and AI capabilities, enabling seamless adoption of smart manufacturing without disrupting existing operations.
Reliable industrial automation starts at the control layer. BEN Engineering designs and implements robust Programmable Logic Controller (PLC) and SCADA systems for process, discrete, and hybrid manufacturing environments — from single-machine control to plant-wide distributed control architecture.
We work with all major platforms — Siemens SIMATIC, Rockwell Allen-Bradley, Schneider Electric Modicon, and Mitsubishi MELSEC — and design systems to ISA-88/ISA-95 standards with built-in redundancy, cybersecurity hardening, and future-proof scalability.
Full-cycle PLC engineering — I/O design, program development in Ladder/FBD/ST, factory acceptance testing (FAT), site acceptance testing (SAT), and commissioning support for all major PLC platforms.
Design and implementation of Safety Instrumented Systems on Siemens S7-F, Rockwell GuardLogix, and Pilz platforms — including HAZOP support, safety requirement specification, and SIL verification.
Servo and stepper motion control for high-precision manufacturing lines — coordinated multi-axis motion, variable frequency drives (VFD), and cam/gearing profiles for packaging, assembly, and CNC applications.
Plant-wide SCADA systems with ergonomic display design (ISA-101 compliant), real-time process trending, alarm management (ISA-18.2), and long-term data historian for regulatory compliance and process analysis.
Custom operator interface panels — from simple touchscreen HMIs to full engineering workstations — with ISA-101 High-Performance HMI design, situational awareness, and context-sensitive navigation.
Industrial network design and integration — PROFINET, EtherNet/IP, PROFIBUS DP, Modbus TCP/RTU, HART, Foundation Fieldbus, and remote I/O panels for distributed plant areas.
From PLC programs to SCADA visualization — every control layer engineered to IEC 61131-3 and ISA standards.
Bridging the gap between shop-floor control systems and enterprise IT is where most manufacturers lose visibility — and profit. BEN Engineering designs and deploys Manufacturing Execution Systems (MES) and enterprise integration layers that connect PLCs, SCADA, WMS, and ERP into a single, coherent data ecosystem.
We implement ISA-95-compliant integration architectures with middleware, REST/SOAP APIs, and OPC-UA connectors — enabling real-time production data to flow seamlessly from the factory floor to ERP dashboards, and business decisions to cascade back into production scheduling.
Full MES deployment including production scheduling, work order management, operator guidance, electronic batch records, and genealogy/traceability — aligned to ISA-95 Level 3 architecture.
Real-time OEE dashboards with Availability, Performance, and Quality breakdowns — automatic downtime reason codes, Pareto analysis, and shift/line/product-level comparison for continuous improvement.
In-line quality data collection, SPC (Statistical Process Control) charting, non-conformance management, and electronic deviation handling — linked to production batches for full traceability.
Directed putaway, wave picking, pack verification, and automated replenishment — with barcode/RFID scanning, cartonization, and real-time slotting optimization for distribution centers and factory stores.
Bi-directional integration between MES/WMS and SAP S4/HANA, Oracle ERP, and Microsoft Dynamics — production order confirmations, goods movements, quality inspection lots, and cost center postings in real time.
Custom integration layers using OPC-UA, REST/SOAP APIs, message brokers (MQTT, RabbitMQ, Kafka), and ETL pipelines — enabling protocol-agnostic connectivity between any operational technology (OT) and IT system.
ISA-95 compliant integration from PLC data to SAP — no batch uploads, no manual entry, no blind spots.
Industry 4.0 transforms the physical factory into a data-driven, self-optimizing system. BEN Engineering helps manufacturers implement IIoT connectivity, AI-powered quality inspection, and predictive maintenance — building on existing control infrastructure without expensive rip-and-replace.
We deploy Industrial IoT edge gateways that aggregate PLC data over OPC-UA and MQTT, apply AI vision systems for inline quality inspection, and use machine learning models for predictive maintenance — reducing unplanned downtime and scrap rates with measurable ROI.
IIoT edge devices that collect data from PLCs, field instruments, and legacy equipment via OPC-UA, Modbus, and serial protocols — aggregating and forwarding to on-premises historians or cloud platforms.
Industrial edge servers for real-time AI inference at the machine — eliminating cloud round-trip latency for time-critical vision inspection and process anomaly detection, with local data sovereignty.
AI-powered inline inspection cameras using deep convolutional neural networks — detecting surface defects, measuring dimensions, and verifying assembly completeness at full production speed.
Machine learning models for process quality prediction — correlating upstream process parameters with downstream quality outcomes to catch out-of-spec conditions before they produce scrap, reducing defect rates and rework costs.
Continuous vibration, temperature, and electrical signature monitoring with ML-based anomaly detection — generating maintenance work orders in ERP automatically when degradation thresholds are crossed, shifting from reactive to predictive maintenance.
Real-time digital twin models synchronized to live plant data — enabling virtual FAT, operator training simulations, what-if process optimization, and predictive scenario planning without impacting production.
Our automation engineers will assess your current systems and design the right integration path — from simple PLC retrofits to full Industry 4.0 transformation.
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