Manufacturing Hub

Artificial intelligence is no longer just a buzzword in manufacturing. The pace of adoption has been incredible, yet the reality is far more complex than flashy headlines suggest. In this episode of Manufacturing Hub, Vlad Romanov and Dave Griffith welcome back Tom Hechtman, founder of Sepasoft, to explore how AI is actually being deployed on the plant floor, what barriers remain, and whether we are truly transforming manufacturing or simply tinkering at the edges.Tom brings decades of experience building MES solutions for manufacturers around the globe. From his early days in the Midwest working with Rockwell Automation technology to launching Sepasoft’s Ignition MES modules and now leading the development of Sepa IQ, Tom has been at the forefront of data, analytics, and system integration. His insights bridge the gap between hype and practice, helping us understand where AI creates real ROI, where it still falls short, and how to build the foundations for success.Throughout the conversation we dive into the challenges of quality improvement, predictive maintenance, scheduling optimization, and contextualizing plant data. We discuss the importance of trust in both data and AI-generated outputs, the economics of running LLMs and machine learning models, and why cybersecurity and data governance cannot be an afterthought. Drawing on the recent MIT study that revealed only 5 percent of AI projects make a measurable P&L impact, Tom helps us unpack what manufacturers need to do differently if they want to avoid being part of the 95 percent that fail.We also get an update on Sepa IQ and how customers are using it to connect plant floor data, structure it for AI and analytics, and prepare for advanced scheduling and predictive tools. From lessons learned working with early adopters to practical advice on starting small, Tom makes it clear that manufacturing AI is a journey that requires technical expertise, domain knowledge, and cultural change.Whether you are an executive evaluating AI investments, a controls engineer curious about new tools, or a plant manager wondering how to get real results, this episode delivers a balanced, practical, and in-depth perspective on the future of AI in manufacturing.Timestamps 00:00 Introduction and AI in every manufacturing conversation 03:00 Tom Hechtman background and the origins of Sepasoft 05:00 MES modules, batch processing, and the evolution of Sepa IQ 08:00 Defining manufacturing AI and the role of plant floor data 13:00 Quality improvement and predictive analytics opportunities 20:00 Foundational challenges with legacy systems and data collection 24:00 Insights from the MIT study on AI adoption and ROI 32:00 Training data, context windows, and the economics of LLMs 44:00 Sepa IQ customer feedback and scheduling optimization 50:00 Trust, hallucinations, and cybersecurity considerations 59:00 ICC announcements, demos, and proof of concept program 1:03:00 Predictions for AI in manufacturing and career adviceReferences mentioned in the episode MIT study on AI in business: https://mitsloan.mit.edu/ideas-made-to-matter/how-to-get-ai-to-pay-off Sepasoft Blog on AI and manufacturing: https://sepasoft.com/blog/ The One Thing by Gary Keller: https://www.the1thing.com/About the guest Tom Hechtman is the founder of Sepasoft, a leading provider of MES modules for the Ignition platform by Inductive Automation. With decades of experience in manufacturing, integration, and software development, Tom has helped companies worldwide improve efficiency, quality, and data visibility. Learn more at https://sepasoft.com/ and connect with Tom on LinkedIn: https://www.linkedin.com/in/tom-hechtman-32b6b66/About the hosts Vlad Romanov is the founder of Joltek, a consulting and integration firm focused on helping manufacturers modernize systems, bridge IT and OT, and drive digital transformation. Learn more at https://www.joltek.com/ and connect on LinkedIn: https://www.linkedin.com/in/vladromanov/Dave Griffith is an industrial automation consultant and co-host of Manufacturing Hub. He works with manufacturers and integrators to identify opportunities, manage digital projects, and build future-ready operations. Connect with Dave on LinkedIn: https://www.linkedin.com/in/davegriffith/If you enjoyed this conversation, make sure to subscribe to Manufacturing Hub for more weekly discussions with industry leaders about automation, digital transformation, and the evolving world of manufacturing.

In this episode of Manufacturing Hub Podcast, hosts Vladimir Romanov and Dave Griffith sit down with Gavin Dilworth to explore the evolving world of ICS and OT cybersecurity. This is a topic that impacts every sector of manufacturing and critical infrastructure, yet many organizations still struggle with where to start, how to assess risk, and how to balance IT and OT responsibilities.Gavin brings decades of experience in automation engineering and cybersecurity, having worked across energy, oil and gas, water, and manufacturing. He shares his unique journey from being an operator and control systems engineer to becoming a specialist in OT cybersecurity. The conversation spans a wide range of issues, from asset inventory and managed switches to people, process, and technology frameworks that help organizations take the first step toward maturity.We discuss why IT and OT teams often clash and what it takes to bridge the gap. Gavin explains the realities of budgets, the challenges of compliance, and why self-reporting frameworks often fail to reflect true maturity. He also highlights the role of legislation in Europe, rising insurance premiums, and how cybersecurity assessments can influence financial and strategic decisions at the executive level.The episode provides clear insights into best practices such as building a proper asset inventory, structuring security awareness training for OT teams, and applying a risk-based approach to patch management. Gavin also outlines the importance of functional safety, process hazard analysis, and the role of frameworks like ISA/IEC 62443. For engineers, leaders, and decision makers, this conversation makes it clear that cybersecurity is not just a technology problem but a people and process challenge that requires long term discipline and investment.If you want to understand what real world OT cybersecurity looks like, what mistakes to avoid, and how to set a path toward resilience, this episode is packed with valuable takeaways.Timestamps 00:00 Introduction and upcoming ICC event 02:20 Gavin’s career journey from operator to cybersecurity expert 06:00 What ICS and OT cybersecurity really mean 09:00 Managed switches, firewalls, and securing industrial devices 11:00 The importance of people, process, and technology in security programs 13:30 Asset inventories and the first practical steps in cybersecurity 17:00 Insurance, legislation, and financial implications of OT risk 23:00 The problem with self reporting and maturity frameworks 27:00 Risk based patching strategies and CVE management 31:00 Physical keys, tokens, and access control challenges 37:00 IT versus OT ownership of cybersecurity 45:00 Certifications, training, and resources for professionals 53:00 Unified Namespace and cybersecurity considerations 58:00 Predictions for the next five years in OT cybersecurity 01:02:00 Career advice for engineers and cybersecurity professionalsReferences mentioned in this episode Industrial Network Security, Eric D. Knapp (Third Edition): https://www.isa.org/products/industrial-network-security-third-edition Security PHA Review: https://www.isa.org/products/security-pha-review-for-consequence-based-cyberse Managing Cybersecurity in the Process Industries, ISA: https://www.isa.org/products/managing-cybersecurity-in-the-process-indust Industrial Cybersecurity: Efficiently secure critical infrastructure systems, Steve Mustard: https://www.isa.org/products/industrial-cybersecurity-efficiently-secure-criti Assessment Plus: https://assessmentplus.co.nz Ignition 8.3 by Inductive Automation: https://inductiveautomation.comAbout the hosts Vladimir Romanov is an electrical engineer and MBA with over a decade of experience in manufacturing and industrial automation. He has worked with Procter and Gamble, Kraft Heinz, Post Holdings, and now leads Joltek, a consulting and integration firm focused on digital transformation and modern manufacturing systems.Dave Griffith is an experienced systems integrator, consultant, and advisor in the industrial automation space. He has worked with manufacturers across multiple sectors, helping organizations align technology with business strategy.About the guest Gavin Dilworth is the founder of Assessment Plus, based in New Zealand. With a background spanning automation, controls, and cybersecurity, he helps organizations design architectures, implement policies, and build resilience in OT environments. He also mentors professionals looking to enter or advance in the ICS cybersecurity field. Connect with him here: https://www.linkedin.com/in/gavin-dilworth/

In this episode of Manufacturing Hub, Vlad and Dave take a deep dive into one of the most critical yet often overlooked aspects of modern manufacturing: network and systems architecture. Too often manufacturers focus on SCADA, MES, and control layers without recognizing that the architecture beneath them is the foundation that determines whether a facility can scale, connect new equipment, and maintain reliability. Architecture touches everything from plant floor PLCs and HMIs to edge devices, managed switches, firewalls, historians, and enterprise-level systems.We begin the conversation by unpacking what “architecture” actually means in manufacturing environments. Is it the hardware, switches, and cables? Is it the way new machines are integrated into existing plants? Or is it the broader strategy of ensuring that data, safety, and scalability are protected? The answer, as both Vlad and Dave explain, is that it is all of these at once.Throughout the discussion, we explore real-world stories where poor architectural decisions led to unplanned downtime, cybersecurity risks, or expensive rework. Vlad shares an example of a palletizer brought online with unmanaged switches and insecure remote access hardware that nearly crippled production until it was properly segmented. Dave recalls his own field experiences, including unusual setups where integrators resorted to improvised remote troubleshooting, highlighting just how creative but fragile some solutions can be.The episode also looks at the evolution of remote access. From the early days of Ewon boxes to modern expectations of secure VPNs, jump boxes, and approved engineering workstations, we discuss what role remote connectivity should play in today’s manufacturing environment. While these solutions can reduce travel time and speed up support, they can just as easily introduce vulnerabilities and trust issues if not carefully managed.From there we move into the technical tradeoffs of device level ring versus star topologies. Vlad explains why he often prefers device level ring to save costs and simplify troubleshooting, while Dave weighs in on the importance of pre-molded cables, managed switches, and long-term maintainability. We also analyze example architectures from Rockwell white papers, pointing out where diagrams align with field best practices and where they differ from what engineers often see in real facilities.Finally, we broaden the perspective by comparing greenfield and brownfield deployments. Greenfield projects allow prime contractors and consultants to design standards up front, but most facilities live in brownfield reality where years of technical debt, unmanaged switches, and ad hoc networks make improvements harder. We also touch on how architecture differs by industry, whether in food and beverage, pharmaceuticals, oil and gas, or distributed environments such as trains or pipelines.The conversation closes with predictions, career advice, and resource recommendations. Vlad stresses that CCNA is still one of the best starting points for engineers who want to understand industrial networking fundamentals, and Dave emphasizes the importance of asking the right questions and learning from experienced peers. Both agree that demand for data, combined with the rise of AI, will continue to stress legacy networks until companies recognize the need for robust, standards-driven architectures.If you work in automation, engineering, IT, or plant management, this episode will give you perspective on why network architecture is not just a technical afterthought but a strategic enabler of digital transformation.Timestamps 00:00 Introduction and community updates 02:30 Defining architecture in manufacturing 05:00 Why networks are the backbone of manufacturing systems 08:00 A real-world palletizer story and the risks of unmanaged switches 14:00 The rise and pitfalls of remote access devices 18:30 Field story of unconventional remote troubleshooting setups 23:00 Who is responsible for network design: end users, integrators, or OEMs 28:00 Analyzing Rockwell’s reference architecture diagrams 36:00 Device level ring versus star topologies in practice 49:00 Brownfield versus greenfield considerations 56:00 Industry-specific architectures from food and beverage to oil and gas 01:04:00 The role of standards and corporate versus local decision making 01:08:30 Predictions, career advice, and recommended resourcesReferences Mentioned in this Episode Ignition Community Conference: https://icc.inductiveautomation.com/ Siemens SPS Atlanta Event: https://new.siemens.com/us/en/company/fairs-events/sps.html Rockwell Automation Architectures and Design White Papers: https://literature.rockwellautomation.com CISSP Official Study Guide: https://www.isc2.org/Certifications/CISSP Winning by Tim Grover: https://www.amazon.com/Winning-Unforgiving-Race-Greatness/dp/1982168862 Cisco CCNA Certification: https://www.cisco.com/c/en/us/training-events/training-certifications/exams/current-list/ccna.htmlAbout the HostsVlad Romanov is an electrical engineer and consultant with over a decade of experience in manufacturing and industrial automation. His background spans global companies such as Procter & Gamble, Kraft Heinz, and Post Holdings, where he has led modernization projects, SCADA and MES deployments, and digital transformation initiatives. He is the founder of Joltek, a consulting firm helping manufacturers align people, process, and technology to improve operations, and he also leads SolisPLC, an education platform for automation professionals. Connect with Vlad on LinkedIn: https://www.linkedin.com/in/vladromanovDave Griffith is a manufacturing consultant and co-host of Manufacturing Hub. With extensive experience in controls, systems integration, and business development, Dave has helped manufacturers across industries adopt SCADA, MES, and digital transformation solutions. He frequently shares insights on IT-OT convergence, operational strategy, and leadership in the automation space. Connect with Dave on LinkedIn: https://www.linkedin.com/in/davegriffithJoltek is a consulting and integration firm that helps manufacturers modernize with clarity, strategy, and execution. Built on decades of hands-on experience in engineering, automation, and plant leadership, Joltek bridges the gap between technical complexity and business value. The team is known for uncovering hidden risks in outdated systems, designing scalable IT and OT architectures, and guiding digital transformation initiatives that actually deliver measurable results. Whether it is upgrading control systems, deploying SCADA and MES platforms, or advising on strategic investments, Joltek consistently brings deep expertise and practical solutions that make manufacturing operations more resilient, efficient, and future ready.Listen and Subscribe Catch every episode of Manufacturing Hub on YouTube and your favorite podcast platforms. 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This week on Manufacturing Hub, Vlad Romanov and Dave Griffith are joined by Kevin McClusky, Chief Technology Architect at Inductive Automation. Kevin shares his journey from computer engineering into the world of industrial automation, his early experiences as an HMI developer, and his leadership roles at Inductive Automation that shaped the direction of Ignition software.The conversation takes a deep dive into the newly released Ignition 8.3 beta, exploring the core features that matter most for end users, system integrators, and manufacturers. Kevin discusses the new Siemens driver with symbolic addressing, the internal historian powered by QuestDB, the Kafka and Event Streams module, and the new DevOps capabilities with file system storage, Git integration, and automated deployments. These capabilities are set to change how manufacturers design, deploy, and scale automation systems in real-world production environments.We also preview the Ignition Community Conference (ICC), which is moving to a larger venue this year. Kevin outlines new additions such as the Hub, the CoLab, community design challenges, and the continuation of Prove It sessions. The episode also covers the evolution of the Build-On competition, the growing integrator ecosystem, and Inductive Automation’s continued focus on empowering its community through transparency and collaboration.This episode provides both a technical and strategic look at where Ignition is heading and why it matters for the future of industrial automation. If you are working on digital transformation, UNS, DevOps for OT, or enterprise-scale SCADA and MES, you will not want to miss this discussion.Timestamps00:00 Introduction and welcome with Dave, Vlad, and Kevin02:00 Kevin’s background and entry into industrial software05:00 Lessons from early HMI and integrator experiences07:30 The importance of integrators in Inductive Automation’s go-to-market strategy09:00 Transition into sales leadership and learnings from global customers13:00 Ignition 8.3 beta release process and development challenges18:00 Historian improvements and introduction of QuestDB21:00 The new Siemens driver and why it matters globally27:00 Use cases for multiple historians and large-scale data performance31:00 Kafka integration, Event Streams, and IT-OT convergence35:00 DevOps capabilities in Ignition including Git and deployment modes41:00 Preview of the Ignition Community Conference and new venue44:00 The Hub, CoLab, and community-driven sessions at ICC50:00 Prove It sessions and exhibitor highlights56:00 The Build-On competition and its evolution01:01:00 Predicting the future of ICC and Ignition01:03:00 Kevin’s career advice for engineers and integrators01:05:00 How listeners can connect with Inductive AutomationReferences Mentioned in the EpisodeInductive Automation: https://inductiveautomation.com/Ignition 8.3 Beta Release Notes: https://inductiveautomation.com/downloads/release-notesQuestDB: https://questdb.io/Opto 22: https://opto22.com/HiveMQ: https://www.hivemq.com/Flow Software: https://flow-software.com/Sepasoft MES: https://sepasoft.com/Soba.ai: https://soba.ai/About the HostsVlad Romanov is an industrial automation consultant, electrical engineer, and founder of Joltek and SolisPLC. With more than a decade of experience in digital transformation and systems integration, Vlad has worked with Fortune 500 manufacturers including Procter and Gamble, Kraft Heinz, and Post Holdings. He is passionate about bridging the gap between IT and OT while helping manufacturers modernize their facilities.Connect with Vlad: https://www.linkedin.com/in/vladromanov/Dave Griffith is a manufacturing consultant and digital transformation strategist who helps organizations navigate technology adoption in automation, data, and operations. With a background in engineering and leadership across multiple industries, Dave focuses on helping manufacturers align technology initiatives with business outcomes.Connect with Dave: https://www.linkedin.com/in/davegriffith/About the GuestKevin McClusky is the Chief Technology Architect at Inductive Automation, where he has played a key role in shaping the growth of Ignition software over more than a decade. Kevin has led professional services, sales engineering, and product strategy, and now focuses on long-term architecture and technology direction for Inductive Automation. He is a frequent speaker at industry events and is deeply involved in guiding the Ignition community.Connect with Kevin: https://www.linkedin.com/in/kevinmcclusky/Manufacturing Hub is a weekly podcast hosted by Vlad Romanov and Dave Griffith, covering digital transformation, automation, data, robotics, and the future of manufacturing. Subscribe to stay ahead in the industry.

Welcome to our special coverage from Automate 2025, recorded directly at the Siemens booth. In this episode of Manufacturing Hub, hosts Vlad Romanov and Dave Griffith sit down with Chris Stevens and Annemarie Breu from Siemens to explore the evolving landscape of manufacturing resilience, digital twins, and automation lifecycle management.This conversation dives into how manufacturers can prepare for disruptions, scale pilot projects into real business outcomes, and adopt technologies that make factories more flexible and robust. Chris highlights the importance of people and processes in delivering exceptional customer experiences, while Annemarie emphasizes how scaling technology deployments creates measurable business impact. Together, they outline how Siemens is helping manufacturers move from isolated pilots to large scale adoption, ultimately strengthening resilience and competitiveness in today’s uncertain environment.We examine the meaning of manufacturing resilience in practice, including how to withstand supply chain shocks, tariffs, and workforce challenges. The discussion also covers workforce empowerment and the need to make manufacturing attractive again, not only by deploying advanced technologies but also by enabling teams to own solutions from the ground up.A major theme is the role of the digital twin. Chris and Annemarie explain why starting in the virtual world is essential to validate designs, optimize processes, and minimize downtime risks. They address how digital twin adoption is becoming more accessible through as a service delivery models and collaborative environments where end users, system integrators, and technology providers all contribute.We also look at the connection between copilot technologies and both operations and engineering. Natural language copilots are enabling operators to troubleshoot equipment quickly and engineers to interact with simulation environments more intuitively. This shift is accelerating adoption while reducing barriers to advanced tools.Finally, the episode touches on automation lifecycle management, drawing parallels to product lifecycle management. By centralizing and version controlling automation artifacts such as PLC programs, HMI projects, and industrial edge applications, Siemens is paving the way for resilient and adaptable operations.If you are curious about the future of resilient manufacturing, digital twins, and adaptive automation, this episode provides both strategic and practical insights.Timestamps00:00 Introduction live from Automate 2025 at Siemens booth01:00 Guest introductions and roles at Siemens02:00 Defining manufacturing resilience in today’s environment04:00 Workforce challenges and empowering teams to drive adoption05:00 Why digital twin is the starting point for resilient operations07:00 Digital twin adoption for small and medium manufacturers09:00 Collaborative engineering environments and the metaverse10:00 Challenges and opportunities at the cutting edge of automation11:00 Copilot technologies for operators and engineers12:30 Connecting digital twins with copilots across engineering and operations13:30 Automation lifecycle management explained14:30 Future deep dive preview on automation lifecycle managementReferences mentioned in this episodeSiemens Digital Industries: https://www.siemens.com/global/en/products/automation.htmlJeff Burnstein and Automate coverage: https://www.automateshow.com/About the hostsVlad Romanov is an engineer, consultant, and co host of the Manufacturing Hub Podcast. With over a decade of experience in manufacturing and industrial automation, Vlad has worked with global companies such as Procter and Gamble and Kraft Heinz, focusing on digital transformation, SCADA and MES deployments, and operational excellence. He also leads Joltek, a consulting firm helping manufacturers modernize operations. Learn more at https://www.joltek.com/Dave Griffith is a consultant and co host of the Manufacturing Hub Podcast. He has extensive experience helping manufacturers and technology companies bridge the gap between strategy and execution, with a focus on scaling digital transformation initiatives. Dave frequently speaks on topics including systems integration, leadership, and the evolving role of technology in industrial operations.About the guestsChris Stevens is responsible for customer experience at Siemens Digital Industries. His focus is on people and processes, ensuring that technology deployments deliver meaningful outcomes, adoption, and long term value for customers.Annemarie Breu leads the Accelerator Deployment Team at Siemens Digital Industries. She specializes in implementing Siemens technologies beyond the pilot stage, scaling adoption, and ensuring that digital solutions create measurable business outcomes.If you enjoy this conversation, make sure to subscribe to Manufacturing Hub for more interviews from Automate 2025 and beyond.

In Episode 221 of Manufacturing Hub, hosts Vlad Romanov and Dave Griffith sit down without a guest to share valuable real-world lessons on data collection, manufacturing intelligence, and implementing solutions that deliver measurable ROI. This episode wraps up the month’s theme on manufacturing intelligence by tying together the insights from previous episodes and putting them into the context of real plant-floor projects.Vlad begins with an in-depth story from his time at Procter & Gamble, where he led an energy monitoring project with the ambitious goal of reducing power consumption by 20 percent. He explains the practical challenges of turning a corporate initiative into an actionable plant-level strategy, from limited baseline data to deciding between standalone meters and integrated monitoring solutions. Vlad shares the lessons learned in balancing cost, data ownership, and scalability, and why a more open solution can sometimes offer greater long-term value than proprietary systems.Dave then takes us into the world of pet food manufacturing, where millions of dollars in raw materials can be lost each year due to inaccurate batching and poor measurement practices. He walks through the process of defining the problem, setting up data collection without overhauling legacy systems, and using that information to identify overages, improve tolerances, and design remediation strategies. The conversation dives into practical engineering decisions, such as when to invest in VFDs for precision dosing, when to redesign process equipment, and how to ensure data insights lead to lasting operational changes.The discussion expands into organizational challenges, including why decision-makers often lack actionable visibility into losses, how to present findings in terms of tangible business impact, and the cultural shift required to actually use the data once it is available. Vlad and Dave also explore examples from discrete manufacturing, where OEE tracking and daily direction setting (DDS) meetings help guide capital allocation, continuous improvement initiatives, and team alignment. They share observations on why some facilities succeed with these systems while others fall back into old habits.Timestamps00:00 Introduction to Episode 221 and monthly theme recap02:00 Vlad’s background and approach to modernization projects04:50 Dave’s background and focus on data-driven manufacturing solutions06:30 Recap of previous episodes on data collection, historians, and MTP/MCP07:30 Vlad’s Procter & Gamble energy monitoring project case study13:40 Addressing power blips, capacitor banks, and ROI considerations19:10 Choosing between proprietary and open monitoring solutions23:40 Dave’s pet food manufacturing story and raw material variance29:50 Methods for data collection without disrupting legacy systems34:20 Improving accuracy, process changes, and remediation strategies44:00 Organizational challenges in acting on data insights52:00 OEE, DDS meetings, and capital allocation in discrete manufacturing59:50 Predictions for the future of manufacturing intelligence and AI integrationReferences MentionedIgnition by Inductive Automation – https://inductiveautomation.com/Ignition Community Conference (ICC) – https://icc.inductiveautomation.com/Procter & Gamble – https://us.pg.com/Rockwell Automation – https://www.rockwellautomation.com/Mettler Toledo – https://www.mt.com/Badwater Ultramarathon – https://www.badwater.com/“Can’t Hurt Me” by David Goggins – https://davidgoggins.com/book/About the HostsVlad Romanov works with manufacturers to modernize operations by bridging the gap between legacy systems and today’s technology. He specializes in assessing current states, designing scalable architectures, and implementing solutions across control systems, SCADA, and MES infrastructures. His mission is to help plants run better from a technical and operational standpoint, whether through unlocking critical data from PLCs or leading full-scale digital transformation initiatives.Connect with Vlad: https://www.linkedin.com/in/vladromanov/Dave Griffith has over 16 years of experience in automation and manufacturing, with a technical foundation in aviation and aerospace. His work spans from OEM manufacturing to food and beverage production, with a strong focus on data-driven projects that deliver ROI. Dave leads teams at Kaplan to unlock operational data, design integration strategies, and deploy solutions that improve efficiencies and reduce waste.Connect with Dave: https://www.linkedin.com/in/davegriffith/

In Episode 220 of Manufacturing Hub, we welcome back Caleb Flanigan to explore one of the most critical yet least understood topics in the evolution of smart manufacturing: MTP (Module Type Package), MCP (Machine Context Protocol), and how they are becoming essential enablers of safe and scalable AI adoption on the factory floor.Throughout this deep-dive episode, we uncover how these emerging standards form the backbone of adaptive plants: facilities capable of safely orchestrating decisions between humans, machines, and AI models. From OPC UA and AutomationML to edge computing and LLM-driven control systems, Caleb explains the architecture, mindset shifts, and implementation considerations that make this vision a reality.Key topics covered include:Why traditional SCADA and MES architectures are not AI-readyThe real-world value of MTP in legacy Brownfield plantsHow Siemens’ Machine Proxy App and OPC UA servers act as translators between AI models and legacy PLCsDifferences between machine states, control interfaces, and orchestrated services in modular manufacturingWhy CLI skills and edge computing are foundational for the modern control engineerHow to pitch digital transformation and AI investments to hesitant executivesWe also touch on organizational psychology, how internal champions get ignored without executive alignment, and the grim future for manufacturers still betting on ice cube relays.Whether you’re a plant engineer, systems integrator, or digital transformation leader, this conversation offers a bold but practical look at how to safely integrate AI into manufacturing control environments: starting with protocols and principles, not just hype.🧠 Resources Mentioned:Siemens Industrial Edge: https://new.siemens.com/global/en/products/automation/industrial-edge.htmlMachine Context Protocol (MCP): https://www.anthropic.com/news/introducing-the-machine-context-protocolVDI MTP Standard: https://www.vdi.de/Book Recommendation: How the World Really Works by Vaclav Smil👤 Guest: Caleb Eastman, Siemens 📌 Theme: Data Foundations and Intelligent Manufacturing 🎙️ Hosts: Vlad Romanov & Dave Griffith✅ Key Timestamps00:00 Welcome Back and Wilborn Celebration 03:30 Caleb's Career Journey from Cisco Cert to Siemens 07:40 Why CLI and Networking Skills Matter in OT 10:00 What Is MCP and Why It Matters for Safe AI 13:00 MTP Overview: The USB of Modular Manufacturing 18:00 Why AI Needs Context-Aware Control Layers 21:00 Bridging Human and AI Control Setpoints 24:30 Brownfield Integration with Siemens Machine Proxy 27:00 Making the Case for AI Investment 31:00 The Future of Safe AI in Manufacturing Plants 36:00 Organizational Resistance and Broken Engineers 42:00 When to Walk Away from Legacy-Only Cultures 46:00 Practical MTP Implementation and Mapping 54:00 Who Maintains MTP and How the Standard Is Evolving 58:00 Predictions: LLMs Will Become Obsolete 01:03:00 Hardware Opportunities and Novel Sensor Startups 01:08:00 Final Thoughts and How to Connect with Caleb

In this episode of Automate 2025, we welcome Bernd Raithel from Siemens back to the show to discuss the evolution of industrial control systems and the future of manufacturing. As the Head of R&D for Siemens Factory Automation in the US, Bernd shares his unique perspective on bridging legacy PLCs with modern IT infrastructure, enabling software-defined automation, and empowering manufacturers with flexible and scalable digital tools. With deep insights into products like the S7-1200, S7-1500, TIA Portal, Sematic X, and Siemens Industrial Edge, Bernd explores how Siemens is supporting everything from small-scale modernization to large-scale transformation.We cover critical trends shaping the next generation of manufacturing, including the rise of virtual PLCs (vPLCs), integration of AI into control systems, the shift from hardware to software-defined automation, and the challenges of IT and OT convergence. Bernd also highlights the importance of version control, DevOps pipelines, and open edge development in making industrial systems more agile.We wrap up by looking at Siemens' global R&D structure, freemium software models for engineers, and how manufacturers can take their first steps into digital transformation—without boiling the ocean.This is a must-watch conversation for engineers, IT leaders, and decision-makers in the automation space looking to understand what the future of control and connectivity looks like.🔗 Mentioned Tools and Technologies:Siemens S7-1200 and S7-1500Siemens TIA PortalSiemens Sematic XSiemens Industrial Edge & Edge Developer KitSiemens UnifiedvPLC (Virtual PLC)CodesysGit-style source control for automationAI Copilots for engineering and operations📍 Timestamps: 00:00 Welcome and intro to Bernd Raithel’s new role 02:00 Siemens legacy in Johnson City and product milestones 04:00 Why software-defined automation is gaining traction 06:00 Edge computing, vPLCs, and building flexible architectures 08:00 The real-world challenges of IT and OT integration 10:30 Sematic X, version control, and agile OT tools 13:00 How Siemens runs global R&D across multiple continents 15:00 The future of manufacturing and PLC longevity 17:00 Balancing modern tools with 30-year lifecycle expectations 19:00 Starting points for digital transformation with Industrial Edge 20:00 Siemens freemium strategy and access to tools for engineers📚 Learn More:Siemens Industrial Edge: https://new.siemens.com/global/en/products/automation/topic-areas/industrial-edge.htmlTIA Portal: https://new.siemens.com/global/en/products/automation/topic-areas/tia-portal.htmlSematic X: https://new.siemens.com/global/en/products/automation/topic-areas/sematic-x.htmlSiemens Unified: https://new.siemens.com/global/en/products/automation/topic-areas/unified.htmlSiemens vPLC: https://new.siemens.com/global/en/products/automation/industry-software/virtual-plc.htmlSiemens Developer Trials: https://plcnext-community.net/

Welcome to Episode 219 of Manufacturing Hub. In this episode, we dive into the evolution of industrial data infrastructure with Jeroen Coussement, Founder and CEO of Factry. Factry is building modern historian and MES software platforms that help manufacturers collect, contextualize, and act on operational data at scale.We unpack the critical role of historians in modern manufacturing environments. While traditional historians focused on archiving time-series data, today’s requirements go far beyond that. Jeroen outlines how a modern historian must fulfill three foundational roles:Efficient high-volume time-series data acquisitionContextual modeling across complex factory assetsDemocratized access and self-service tools for operations teamsThis episode covers:The differences between SCADA, MES, and historiansThe evolution from legacy platforms like OSIsoft PI to cloud-native historiansArchitectures for on-prem, cloud, and hybrid historian deploymentsReal-world use cases like wind turbine optimization for shadow flicker mitigationCommon challenges in digital transformation, including network modernization and change managementHow manufacturers can scale from data collection to full analytics enablementJeroen also shares why point solutions often lead to fragmentation, and how building a robust data foundation opens the door to advanced tools like AI, unified namespace, and better decision-making.📍 Guest: Jeroen Coussement, Founder and CEO at Factry🌐 https://www.factry.io📚 Resources Mentioned:Factry Historian: https://www.factry.io/products/factry-historianIT/OT Insider: https://insider.itot.ioCanary Historian: https://www.canarylabs.com/AVEVA PI System: https://www.aveva.com/en/solutions/pi-system/GE Proficy Historian: https://www.ge.com/digital/applications/historianJoltek Consulting: https://www.joltek.com/⏱️ YouTube Timestamps00:00 Intro and welcome02:00 Jeroen’s journey from bioscience engineer to founder of Factry05:00 What is an industrial historian and why it matters09:00 The relationship between SCADA, MES, and historians12:00 Legacy historian vendors and what’s changing15:00 The shift to cloud-native and open data systems18:00 When and why manufacturers choose to implement a historian21:00 Software cost vs implementation cost23:00 Common historian architectures: on-prem, cloud, hybrid27:00 Regional differences in adoption across US and Europe30:00 Use case: Wind turbine shadow flicker mitigation via historian35:00 Can historians ever feed data back into PLCs?39:00 Change management and user training are key42:00 Layering MES and quality tools on top of a historian46:00 Why point solutions fail and unified platforms win49:00 Empowering domain experts with self-service analytics52:00 Predictions for the future of historians54:00 Career advice for those entering the industrial data space56:00 Who should reach out to Factry

Data collection is no longer a back-office task. It is now the foundation of manufacturing intelligence. In this episode of Manufacturing Hub, we are joined by Brian Bribe, founder of Mach Controls, to explore the practical realities of modernizing data infrastructure inside manufacturing facilities.Brian brings a frontline perspective to OT architecture and walks us through what it actually takes to connect legacy equipment, build scalable pipelines, and enable true real-time decision-making. We dive deep into Unified Namespace (UNS) principles, the evolution of MQTT and Kafka in industrial settings, and why so many manufacturers struggle to get ROI from new digital systems. From co-op student to founder of a systems integration firm, Brian shares how his early hands-on experience shaped his understanding of controls, business systems, and the gaps in between.Topics include historian layers, challenges with SCADA-based centralization, how to scope a machine connectivity project, practical change management tips, and the path to flattened architectures using modern pub-sub tools. This is a must-watch for engineers, plant managers, and decision-makers looking to make sense of the data revolution inside their factories.📌 Episode 217 is the first in our July theme focused on Data Collection for Manufacturing Intelligence.🔗 Learn more about Manufacturing Hub: https://manufacturinghub.live🔗 Explore Joltek consulting services: https://www.joltek.com/⏱️ Timestamps00:00 Introduction and Overview of Data Collection Theme02:00 Brian’s Journey into Controls Engineering and Integration06:30 What Legacy Manufacturing Equipment Actually Looks Like10:00 Why Data Collection is Often an Afterthought in Scope13:50 The Disconnect Between Machines and Business Systems17:00 Real-World Discovery Process for Machine Connectivity22:00 Overcoming Internal Resistance to Data-Driven Projects28:00 Strategies for Extracting Data from Obsolete PLCs34:30 Direct Sensor to SCADA vs PLC-Driven Design Debate41:00 Flattening the Architecture and Breaking the Purdue Model55:00 What Unified Namespace Looks Like in Practice with UMH

In this episode of Manufacturing Hub, we welcome back Pawel Krupa, founder of the Future Robotics YouTube channel, to dive deep into the rapidly evolving world of industrial robotics. With over a decade of hands-on experience integrating and programming systems from Fanuc, KUKA, and others, Pawel shares exclusive insights on some of the biggest changes reshaping robotics in 2025. These changes are not just cosmetic updates; they are being driven by new ISO standards and increasing cybersecurity requirements across industrial automation.We explore the hardware and software changes coming to Fanuc’s R-50iA cabinet, including multiple Ethernet ports, enhanced vision systems with built-in lighting, and a groundbreaking integration of Python for native robot programming. KUKA is also undergoing a major transformation with its KC5 slim cabinet and KUKA iiQ OS, a Linux-based control system with new UI, simulation environments, and plug-and-play capabilities. These updates signify a paradigm shift where robots become not only smarter and safer, but far easier to configure, maintain, and upgrade.The conversation expands into one of the most talked-about frontiers in robotics: humanoid robots. Are they just hype or do they have a real role to play in industrial environments? We assess the business case for humanoids, especially in facilities where traditional automation has been financially unjustifiable. From handling tasks like herb sorting in food production to stepping into high-risk environments, humanoids may soon bridge the automation gap in low-throughput, labor-intensive workflows.We also explore how AI is influencing robot deployment, from edge vision systems to cycle time optimization. Pawel outlines how drag-and-drop AI-powered tools are slashing development time for vision systems from hours to minutes, while also lowering the barrier to entry for those without years of machine vision experience. Vision systems that used to require complex calibration and scripting are now being trained on real-time images or CAD models, making robotic integration faster and more accessible than ever.Finally, we close with actionable startup ideas and a bold look into the future of collaborative robots, AI, and hybrid ecosystems of humanoids and industrial arms working side-by-side. If you're in automation, manufacturing, or considering a robotics venture, this episode is packed with strategic insight, technical knowledge, and forward-thinking ideas you won’t want to miss.🔗 Explore more from Pawel Krupa: https://www.youtube.com/@FutureRobotics🎙 Manufacturing Hub Archives: https://www.manufacturinghub.live/💡 Joltek Consulting Services: https://www.joltek.com/⏱️ Timestamps00:00 – Intro and Overview of Robotics Coverage03:00 – Pawel Krupa Introduction and Robotics Background05:00 – Cybersecurity-Driven Changes to Industrial Robots06:30 – Fanuc R-50iA Cabinet Updates and Python Integration11:00 – KUKA KC5 and iiQ OS: New Hardware and Software Paradigm15:00 – ISO Changes and Safety Implications for Cobots17:00 – Industrial Applications and ROI for Humanoid Robots30:00 – Practical AI Use Cases in Robotics and Vision Systems40:00 – AI Vision System Setup: From Demo to Deployment49:00 – Startup Idea: Optimizing Robot Motion via AI57:00 – Future of Robotics: AI-Enabled Humanoids and Maintenance Bots

Welcome to another episode of Manufacturing Hub! In this week’s episode, we dive deep into the evolving world of robotics with returning guest Sean Dotson, now CEO of Elite Robotics. From building large-scale material handling systems to exploring the future of AI-driven robot programming, Sean shares a candid view of what it really takes to modernize factory operations.We explore:What “material handling” really means in practiceThe real-world complexity of end-of-arm tooling and vision systemsWhy standardization is critical for both integrators and manufacturersWhat robotics programming and automation roles will look like in the next five yearsThe practical limits of robots-as-a-service and humanoid hypeUsing generative AI and GPTs to assist in controls programmingCareer advice for engineers breaking into robotics and automationPlus, Sean shares some incredible stories from the field, including building a machine for radioactive seed sorting and handling rocket-propelled grenade components safely with robots. 🔥Whether you're an engineer, systems integrator, or a manufacturing leader, this episode offers tactical insights and thoughtful strategy.🔗 Learn more about Sean’s company: https://eliterobotics.com📫 Contact Sean directly: sean@eliterobotics.com🔗 Connect with Vlad: https://www.linkedin.com/in/vladromanov🔗 Learn more about Joltek: https://www.joltek.com

In this episode of Manufacturing Hub, we welcome back Billy Albritton for a deep dive into the evolving world of artificial intelligence in manufacturing. Billy first joined us on Episode 23, and now almost 200 episodes later, he returns to share his perspective on how far the space has come and what the future holds.Billy walks us through his journey from the military to advanced manufacturing and ultimately to becoming a leading voice in the AI and digital transformation space. We explore how large language models like ChatGPT are already changing how we write code, design solutions, and even train junior engineers. He offers real-world use cases of generative and agentic AI in industrial contexts and explains how tools like Cursor are already being used to automate everything from software development to curriculum generation.We unpack the cultural barriers that prevent AI from being adopted on the plant floor and how forward-looking companies can implement AI safely and ethically. From internal teams building custom tools to small agile firms delivering big results, the conversation highlights the shift in power and opportunity across the ecosystem.Billy also gives us a glimpse into the near future of AI-enhanced humanoid robots, local LLM deployments on the shop floor, and what might happen to traditional job roles as these technologies scale. Whether you are an engineer, developer, plant manager, or simply curious about how AI is impacting the real world, this episode will give you both insights and practical strategies to consider.Stick around until the end to hear Billy’s predictions for the next five, ten, and twenty years in manufacturing. And if you’re wondering how to get started with AI tools, Billy offers concrete advice and resources you can begin exploring today.Timestamps: 00:00 Welcome back Billy Albritton 02:00 Billy’s path into manufacturing and robotics 06:00 How ChatGPT shifted Billy’s perspective 10:00 What is agentic AI and why it matters 15:00 The changing role of junior developers 20:00 AI in traditional enterprise software vs the real factory floor 27:00 Challenges with industrial AI adoption 32:00 Internal vs external development strategies 37:00 Billy’s go-to AI tools and workflows 45:00 Real-time AI assistants and the new software paradigm 53:00 Is there a ceiling to generative AI? 59:00 The future of robotics and humanoids 1:03:00 What happens to work in a post-AI world? 1:06:00 Advice for anyone looking to start with AI todayConnect with Billy https://www.linkedin.com/in/billyalbritton/Follow us Host: https://www.linkedin.com/in/vladromanov/ Show: https://www.manufacturinghub.live/ Joltek: https://www.joltek.com/Recommended Tools Mentioned Cursor: https://www.cursor.so/ OpenAI ChatGPT: https://chat.openai.com/ Claude by Anthropic: https://claude.ai/ Synthesia: https://www.synthesia.io/ Hugging Face: https://huggingface.co/ Leonardo AI: https://leonardo.ai/Subscribe for more conversations with the most innovative minds in manufacturing and industrial automation. New episodes every Thursday.

AI is making headlines across every industry, but how much of it is actually being used on the manufacturing floor?In this episode of Manufacturing Hub, Vlad and Dave return to the whiteboard to explore practical and real-world applications of artificial intelligence in manufacturing. From pre-operations to live production, this session covers how AI is being used today across CAD tools, BOM generation, predictive maintenance, system optimization, and machine vision. We also talk through the risks, the limitations, and what still requires human judgment.We begin with design tools and programming before the machine even starts. Then we move through how AI is being used during operations for tasks like work order creation, failure detection, and PLC coding assistance. We explore real use cases for predictive maintenance and ask the tough question: what value are companies actually getting from this technology? Later in the episode we shift into optimization strategies. How can AI help increase throughput or reduce energy costs based on historical data? What does it take to apply these methods in mid-market factories, not just Fortune 100 environments?We also dive into quality inspection and machine vision. These applications are among the most mature in manufacturing today, and we break down examples like barcode inspection, defect detection, and using AI to adapt based on customer complaints. Throughout the episode we share insights from the field and address audience questions about generative AI, simulation tools, and where human expertise still matters most.Referenced in this episode Phoenix Contact case study from Episode 173: https://www.youtube.com/watch?v=ZoQjowwDi2M Siemens and Microsoft Copilot initiative Emerson, Bentley Nevada, and GE predictive maintenance platforms University of Tennessee Reliability and Maintainability Center: https://www.rmc.utk.edu UR and Spectral vision systems seen at Automate 2025 Teledyne and Cognex AI-based machine vision tools Cone GAVIN and Siemens Process Simulate Joltek – consulting for manufacturing strategy, automation, and digital transformation: https://www.joltek.com/This is Episode 212 of Manufacturing Hub, your go-to resource for conversations between real practitioners in industrial automation and manufacturing. Join us live every Wednesday at 4 PM Eastern and follow along on YouTube, LinkedIn, and all major podcast platforms.

In this special edition of Manufacturing Hub, we take you inside one of the most transparent and technically rigorous events in industrial automation: ProveIt 2025.Created by Walker Reynolds and the team at 4.0 Solutions, ProveIt brings together 36 vendors to solve real manufacturing problems inside a live virtual factory environment. Everything is connected through a Unified Namespace and powered by real-time MQTT infrastructure.Unlike traditional expos, ProveIt is not about product demos. It's about execution. Vendors were given access to production data, a shared namespace, a deadline, and a challenge: prove your solution works—live, with full transparency around time, cost, and outcomes.Featured GuestsWe speak with industry leaders and innovators including:Walker Reynolds from 4.0 SolutionsTravis Cox from Inductive AutomationBenson Hougland from Opto 22Caleb and Sophia from Siemens (WinCC OA and Industrial Edge)Mark and Harry from Tatsoft FrameworksAnd many more voices from across the Manufacturing Hub communityWhat You'll LearnWhy ProveIt is reshaping the way we evaluate industrial techHow Unified Namespace is implemented at scaleReal examples of cost, delivery time, and performance dataBuilding resilient MQTT architectures for edge-to-cloudAI and machine learning use cases that go beyond dashboardsWhy transparency and interoperability matter more than everLessons in vendor selection, technical strategy, and scalabilityHow real manufacturers are architecting their next-gen stacksExplore the Technologies FeaturedProveIt and 4.0 Solutions https://www.40solutions.com https://www.proveit.liveUNS and Industry 4.0 Learning https://www.iiot.university https://www.youtube.com/@4.0SolutionsMQTT Infrastructure HiveMQ – https://www.hivemq.com Tatsoft Frameworks – https://tatsoft.comSCADA and Edge Platforms Inductive Automation – https://inductiveautomation.com Opto 22 – https://www.opto22.com Siemens WinCC OA – https://new.siemens.com/global/en/products/automation/industry-software/automation-software/scada/wincc-open-architecture.html Siemens Industrial Edge – https://www.siemens.com/global/en/products/automation/industrial-edge.htmlCloud and Data Services Google Cloud for Manufacturing – https://cloud.google.com/solutions/manufacturing Dell NativeEdge – https://www.dell.com/en-us/dt/solutions/edge-computing/nativeedge.htm Snowflake Manufacturing Solutions – https://www.snowflake.com/solutions/industry/manufacturing Litmus Edge AI – https://litmus.io Tulip Interfaces – https://tulip.coCommunity and ResourcesIndustry 4.0 Discord https://discord.gg/industry40IOT University Mastermind Program https://iot.universityMore Episodes of Manufacturing Hub https://www.youtube.com/@ManufacturingHubFinal ThoughtsProveIt is not just a conference. It is a full-scale test bed for what's possible in modern manufacturing. Real data. Real time. Real constraints. Real answers.If you want to see how the best in the industry are building the next generation of manufacturing architecture, this is the episode to watch.Let us know which vendors impressed you most. What technologies are you excited to explore? And what would you like to see proved next year?Thank you for being part of the Manufacturing Hub community.

Welcome back to Manufacturing Hub! In this special episode, we dive into an Automate 2025 preview, joined by Brian Priebe from Mach Controls and James Brown from 4IR Solutions.We break down what to expect at Automate next week in Detroit (May 12 to 15), booth highlights, technology trends, and hands-on insights into cutting-edge industrial solutions like Unified Namespace, Dockerized PLCs, AI applications in manufacturing, and more.Topics discussed:✅ What's new at Automate 2025✅ The Mach Controls ProveIt demo✅ Building practical data infrastructure for manufacturers✅ Unified Namespace architecture and UMH✅ Docker containers in industrial environments✅ AI's real potential in manufacturing operations✅ How small to mid-size manufacturers can advance digital maturity✅ 4IR Solutions’ Factory Stack offerings✅ Best practices for building scalable, future-proof architecturesGuest highlights:🔹 Brian Priebe, President of Mach Controls🔹 James Brown, CEO of 4IR SolutionsReferencesAutomate ShowUnited Manufacturing HubInductive Automation IgnitionOpto 22Phoenix ContactBooth locations at Automate 2025:Siemens Booth #3232Phoenix Contact Booth #5232Inductive Automation Booth #3452If you’re attending Automate, be sure to stop by these booths to check out demos, meet the community, and explore how modern architectures are shaping the future of manufacturing!Join the conversation:Are you exploring AI, Unified Namespace, or modern data architectures in your plant? Drop your questions or comments below!Follow us:https://www.manufacturinghub.liveJoltekFRAME

In Episode 209 of Manufacturing Hub, we sit down with Dylan to explore the full spectrum of automation—from his early hands-on experiences in PLC programming all the way to architecting full-scale SCADA and MES systems. If you're looking to understand what it really takes to grow a career in industrial automation, this conversation delivers raw insights, practical lessons, and battle-tested strategies from the plant floor to the boardroom.Dylan shares how his career evolved from service technician to systems integrator, detailing the learning curve involved in jumping between platforms like Ignition, FactoryTalk, Wonderware, and SQL databases. We dig into real-world project challenges, the importance of simulation and testing, and what it means to deliver systems that operators actually enjoy using. Along the way, Dylan offers valuable advice on how to learn faster, deal with unclear project scopes, and design better user interfaces by borrowing principles from modern UX and UI design.We also examine:Why ownership and internal technical teams are critical for end usersThe importance of interoperability and avoiding vendor or integrator lock-inHow project creep really happens and what you can do about itVisualization trends in SCADA and HMI systems, including practical opinions on high-performance design and AR/VRData strategies for manufacturing, from pipe-level decisions to planning for future use casesDylan’s new venture, Abelara, and how it helps manufacturers align executive vision with plant-floor executionThis episode is a must-listen for engineers, integrators, and manufacturing leaders looking to modernize their operations while keeping both usability and scalability in mind. Whether you’re early in your automation career or navigating complex transformation efforts, you’ll walk away with insights you can apply immediately.⏱ Timestamps:00:00 – Introduction00:08 – What is Manufacturing Hub? Meet Dylan, our guest02:00 – Dylan’s career path from tech school to SCADA systems04:00 – Early project experience and rapid on-the-job learning06:30 – Moving from PLCs to SCADA and MES development08:20 – Learning without mentors: forums, support lines, and trial by fire10:10 – Challenges and opportunities with modern control platforms12:00 – Vendor openness, interoperability, and practical system limitations15:00 – Scope creep and how to reduce it with better project planning17:00 – The role of simulation and show-and-tell in successful startups20:00 – Getting end user buy-in from operators to executives22:15 – UI and UX in industrial systems: beyond standards and templates26:00 – Why most HMI screens are outdated and how to improve them30:00 – Using consumer design trends in industrial HMI development33:00 – Ownership vs. partnership: the evolving role of integrators36:00 – Visualization tools: what's working and what still needs to improve40:00 – Data in manufacturing: planning, silos, and interoperability45:00 – Why planning trumps tools and how to avoid duplicate systems49:00 – Real talk on end user responsibility and integrator lock-in54:00 – How local integrators can thrive in a reshoring environment57:30 – Early signs and implications of reshoring in manufacturing01:01:00 – Introducing Abelara: Dylan and Glenn’s new consulting venture01:04:00 – Book recommendation: Silos, Politics and Turf Wars01:06:00 – Career advice for new engineers: learn by doing01:09:00 – Final thoughts and how to connect with Dylan and Abelara📘 Book Mentioned:Silos, Politics and Turf Wars by Patrick Lencioni – A foundational read for breaking down barriers and aligning teams across departments.🎙 Learn more about Dylan and his work at Abelara: https://abelara.comCheck out the manufacturing newsletter - https://www.framexl.com/Subscribe for weekly conversations with experts pushing the boundaries in automation, controls, manufacturing systems, and digital transformation.

In this episode of Manufacturing Hub, co-hosts Vlad and Dave turn the spotlight on themselves and share deeply practical stories from the front lines of industrial transformation. With decades of experience consulting across manufacturing verticals, they unpack some of the most pressing (and often misunderstood) topics shaping the future of factories today—from aging infrastructure and insurance-driven cybersecurity to real-world applications of artificial intelligence and organizational change.If you're a plant manager, controls engineer, systems integrator, or digital transformation leader, this episode delivers grounded, no-fluff advice you can apply right away.🧠 Key Themes & Topics Covered:🔐 Cybersecurity as a Financial Decision:Vlad explains how cybersecurity initiatives often originate from IT and are directly influenced by rising insurance premiums, making cyber-risk quantifiable. Learn how assessments now inform insurance underwriting and why updating your legacy OT systems could lower your premiums and risk exposure.🛠️ Obsolescence Assessments & Risk-Based Planning:Explore the actual workflow of auditing plant-floor systems, from identifying unsupported PLCs (like PLC-5s or Data Highway+) to negotiating priorities between IT directors, engineering teams, and insurance firms. Vlad shares real examples of balancing modernization costs with production constraints and process uptime.📊 Why Assessments Are Just the Beginning:Understand how post-audit phases translate into strategic proposals that combine low-hanging fruit projects with long-term roadmaps. Learn how organizations build 3–5 year modernization strategies—without bringing operations to a halt.🤖 AI Strategy in Manufacturing—Beyond the Hype:Dave shares how enterprise leaders—from CEOs to HR and IT departments—are approaching AI with curiosity but confusion. He outlines a clear framework for structuring executive workshops, evaluating tools, and identifying high-impact use cases across functions (from maintenance to HR to accounting).🧩 AI Agents, Co-Pilots, and the Future of Decision-Making:Explore the evolving role of AI agents and LLM-based tools on the shop floor. Dave breaks down what AI agents are, how they might function in the future (e.g., executive dashboards that talk back), and what security hurdles still block widespread deployment in industrial settings.⚠️ The Reality of Change Management:Implementing new tech is hard. Dave discusses how real change happens only when frontline champions (not just executives) see personal value in new tools. Hear the story of how one skeptical veteran technician became a project’s biggest advocate—once it solved a pain point he had lived with for decades.🔁 IT/OT Alignment & Organizational Silos:The hosts discuss why most enterprise-scale modernization efforts stall—not due to technical complexity, but due to siloed budgets, conflicting incentives, and competing visions between digital transformation leads, IT VPs, and plant operations.⏱️ Timing Is Everything:Even with budget in hand, projects often face delays due to scheduling around critical uptime windows. Vlad explains how production planning often dictates digital progress, especially in lean operations like food & beverage and life sciences.🎯 Who This Episode Is For:Engineering & operations leaders navigating legacy infrastructureCybersecurity professionals responsible for OT risk mitigationPlant managers balancing uptime with modernization goalsDigital transformation executives driving multi-year initiativesSystem integrators and consultants supporting migration projectsAnyone curious about how AI is actually being evaluated in manufacturing📢 Don’t forget to:✅ Like this episode if you learned something📝 Comment with your thoughts or questions🔔 Subscribe for weekly episodes exploring the frontlines of manufacturing🎧 Listen on Spotify, Apple Podcasts, or your favorite platform

In this episode of Manufacturing Hub, we welcome Amy Williams, Systems Architect at Skellig, for a deep dive into the world of life sciences manufacturing, a rarely explored but incredibly complex part of the industrial landscape.From her roots in biomolecular chemical engineering to her hands-on role in Operation Warp Speed, Amy walks us through what it's really like to build and validate manufacturing systems for pharmaceutical and biotechnology applications under FDA regulation. 💊🧪We explore:What exactly qualifies as "life sciences" in manufacturingWhy GMP compliance and validation are critical, and how they slow everything downHow Operation Warp Speed succeeded in compressing a 10-year process into monthsThe role of automation, MES, and DCS in life sciencesWhy paper-based MES is still sometimes the fastest way forward (and why that needs to change)How companies are moving toward digitization, better data exchange, and process analytical technology (PAT)Amy also shares her thoughts on:The importance of cross-functional collaboration in regulated environmentsTips for engineers looking to break into the life sciences spaceWhy owning your control code might be more valuable than you thinkIf you're in automation, MES, or engineering leadership, and especially if you work in or around FDA-regulated industries—this episode is a must-listen.🎧 Subscribe for more practical conversations at the intersection of manufacturing, automation, and strategy.🔗 Connect with Amy: https://www.linkedin.com/in/amy-williams-automation📚 Book Recommendation: The Technology Fallacy

We’re kicking off a new theme—Faces You Should Know in Manufacturing—with none other than Ryan Cahalane, Managing Partner at Axiom Manufacturing Systems. Ryan’s path through manufacturing is anything but ordinary: from plant floor engineering at Goodyear, to leadership roles at GE, Rockwell Automation, OSIsoft, and more, Ryan has worked every angle of the manufacturing ecosystem.In this episode, Ryan joins Dave and Vlad to unpack the biggest real challenges manufacturers are facing today—not the buzzwords, not the hype, but the deep, persistent problems slowing progress across the industry.We discuss:Why there’s no one-size-fits-all solution—and why misalignment is more common than we admitThe skill gap crisis: it’s not just about training, it’s about pay, experience, and opportunityThe AI distraction: why most companies aren’t ready, and how AI is best used today in manufacturingThe dangers of LinkedIn echo chambers and shiny object syndrome in tech selectionWhy engineers struggle to move into consulting—and why they shouldn’t be afraid to tryThe unique challenges (and hope) in mid-market manufacturing—and how nimble companies can still winThe need for a Sherpa, not a savior: how consultants should support, not dictateRyan’s story is filled with rich personal insights: from trading stocks and working at Deloitte, to recovering from a stroke and launching Axiom, he brings a grounded, field-tested perspective that connects strategy, operations, and technology in ways few others can.If you're a plant manager, engineer, executive, or someone who helps manufacturers grow—this conversation will challenge your assumptions, validate your experiences, and probably make you laugh.This isn’t just another talk about “digital transformation.” It’s a real look at what it takes to lead, adapt, and deliver in a manufacturing world that refuses to sit still.