From Automation to AI: Our Partnership with InflexionPoint

“We are proud of this partnership because it is built on real exchange. InflexionPoint understands American manufacturing at a depth that takes decades to build. We bring a different engineering perspective — and together we have delivered things neither team would have reached alone.”

“HebronSoft invested their time, effort, and resources to understand our needs and requirements while designing our solution. They are a client-oriented, smart, creative, and reliable technical advisor and software development partner. Their team challenged ours to simplify the user experience and always asked probing questions that improved the overall design and architecture of our cloud-based solution. I can’t say enough good things. They are a pleasure to work with, always go above and beyond, and I look forward to future collaborations.”

InflexionPoint is an independent systems integrator with over 40 years of experience in industrial automation and Industry 4.0. Founded in 1983 as Automated Control Concepts, the company rebranded to reflect its expanded focus on digital transformation, industrial AI, and manufacturing intelligence. Recognized on the Inc. 5000 list of America’s fastest-growing private companies and backed by Sverica Capital Management, InflexionPoint serves manufacturers in Life Sciences, Food & Beverage, and Critical Infrastructure.

Industrial Automation & SCADA

Our collaboration began with industrial automation projects — HMI/SCADA systems, Ignition integrations, and operator interface development for manufacturing environments.

Manufacturing Intelligence — Unified Industrial Data Platform

The engagement deepened into designing and building a unified industrial data platform bringing together Ignition SCADA, TruTraq, LabOWL, and Smart Start into a single, cloud-based environment.

Life Sciences & Pharma Manufacturing

As InflexionPoint expanded into regulated manufacturing, HebronSoft followed —delivering engineering work across Fill & Finish systems, MES platforms, LIMS, and SCADA for gene therapy production for pharmaceutical and biotech manufacturers in the US

Today — Exploring Industrial AI

Our most recent collaborations explore what industrial AI can become: predictive maintenance for pumps, real-time bioreactor monitoring, and AI-powered medical image analysis — integrated with Ignition SCADA and built on Python-based ML pipelines.

*End-client names are withheld in compliance with our confidentiality agreements.

Through our partnership with InflexionPoint, HebronSoft has delivered engineering work across regulated pharmaceutical and biotech manufacturing environments — where data integrity, traceability, and GMP compliance are core requirements.

Gene therapy manufacturing operates under some of the strictest regulatory and quality requirements in the pharmaceutical industry. Parameters must be traceable, process deviations captured, and all equipment monitored in real time — with systems reliable enough to support GMP compliance across the entire manufacturing workflow.

A global pharmaceutical company needed to expand manufacturing capacity for a new gene therapy product. The objective was to implement a scalable SCADA system supporting fill and finish operations — enabling real-time monitoring, control, and data acquisition while ensuring precise process oversight, data integrity, and regulatory compliance, with centralized visibility into all critical equipment and utilities.

What We Built

HebronSoft extended the existing local HMI interfaces, designing and developing a web-based Fill & Finish Control System on Ignition Perspective SCADA. The solution implemented separate monitoring screens for each medicine production line, with full data security, error handling, alarm management, and historian implementation across the facility.

Three Areas of Impact

Unified Equipment Visibility. A centralized web-based portal provides real-time visualization of all manufacturing processes across all facilities — giving management and quality teams a single view of every production line at any moment.

Operator-Centric Experience. Operators and engineers can monitor all product manufacturing stages, device statuses, and historical process data from a single point of access — eliminating the need to switch between systems and reducing the risk of missed information during critical production phases.

Risk Care. Alarm notifications, on-screen trend visualization, and clear parameter indicators give operators the information they need to respond proactively — before deviations become failures. In a gene therapy manufacturing environment where batch integrity is non-negotiable, this is a compliance requirement.

Technologies: Ignition Perspective SCADA, SQL Bridge Module

Results

A comprehensive control system for pharmaceutical fill and finish operations, supporting Final Drug Product filling, viral vector aliquoting, and media distribution across multiple modes. Built on Rockwell CompactLogix PLC with PackML sequence logic and Ignition Perspective SCADA — covering recipe creation, calibration, versioning, alarm management, historian, and audit trails.

• 75% improvement in situational awareness through centralized operational visibility
• 40% reduction in operator intervention time through support for both manual and automated operation modes
• 25% acceleration of data-driven decisions through intuitive HMI design and real-time trend analysis

A fully compliant Laboratory Information Management System workflow within TrakSYS — end-to-end sample lifecycle management, test order and result tracking, audit trails, and regulatory readiness for a biotech manufacturing environment.

• 100% digital sample traceability, reducing manual tracking by 60% and process deviations by 40%
• 60% reduction in operational disruptions through elimination of legacy defects
• 30% improvement in planning accuracy through structured backlog governance

Our client is one of the world's largest consumer health companies — a global manufacturer whose brands are trusted by over 1.2 billion people worldwide. The company operates across multiple product categories including personal care, wellness, and over-the-counter health products, with manufacturing operations subject to stringent quality and regulatory requirements.

Full replacement of a legacy manufacturing management system with TrakSYS — covering weighing, dispensing, compounding, and filling processes with Electronic Batch Record generation, SAP integration, and label template creation. System integration testing, user acceptance testing, and hypercare support delivered.

Discovery and architecture for a next-generation web-based industrial connectivity platform — containerized client deployments, multi-protocol industrial driver support, centralized licensing and entitlement management across multiple clients.

Technologies: .NET 8, EF Core 8, PostgreSQL.

Beyond traditional automation delivery, our teams have explored new applications of artificial intelligence in manufacturing environments — applying machine learning to real-time sensor data, bioprocess optimization, and medical image analysis.

Predictive Maintenance for Industrial Pumps

AI-powered real-time sensor analysis integrated with Ignition SCADA. The system continuously monitors pressure, temperature, vibration, and flow rate, using trained machine learning models to predict failures before they occur and trigger automated alerts when risk thresholds are exceeded. Technologies: Python, TensorFlow, PyTorch, Scikit-Learn, PostgreSQL, Flask.

AI-Powered Bioreactor Monitoring

Real-time prediction of dissolved oxygen, pH, pressure, and cell growth trends in bioreactors — integrated with Ignition SCADA through a Python-based predictive analytics API. The system forecasts process deviations before they occur, enabling preemptive corrections and optimizing bioprocess performance.

AI-Powered Medical Image Analysis

Deep learning system integrated with Ignition SCADA for automated classification and quantification of blood cell types from real-time microscopic images — supporting laboratory diagnostics and research workflows with high-accuracy models and automated reporting.

From connected factories to AI-powered manufacturing systems, our partnership with InflexionPoint continues to evolve alongside the industries we serve. We believe the future of manufacturing will be more intelligent, more integrated, and more human-centered — and we are proud to help build it together.

The best partnerships we have are the ones where both sides grow. InflexionPoint is part of the Hebron ecosystem — a network of companies and organizations that believe engineering and social impact are not opposites.

Explore our Impact →