Ep. 209 - From PLCs to SCADA and MES Dylan's Real-World Journey Through Modern Manufacturing Systems

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 users

The importance of interoperability and avoiding vendor or integrator lock-in

How project creep really happens and what you can do about it

Visualization trends in SCADA and HMI systems, including practical opinions on high-performance design and AR/VR

Data strategies for manufacturing, from pipe-level decisions to planning for future use cases

Dylan’s new venture, Abelara, and how it helps manufacturers align executive vision with plant-floor execution

This 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 – Introduction
00:08 – What is Manufacturing Hub? Meet Dylan, our guest
02:00 – Dylan’s career path from tech school to SCADA systems
04:00 – Early project experience and rapid on-the-job learning
06:30 – Moving from PLCs to SCADA and MES development
08:20 – Learning without mentors: forums, support lines, and trial by fire
10:10 – Challenges and opportunities with modern control platforms
12:00 – Vendor openness, interoperability, and practical system limitations
15:00 – Scope creep and how to reduce it with better project planning
17:00 – The role of simulation and show-and-tell in successful startups
20:00 – Getting end user buy-in from operators to executives
22:15 – UI and UX in industrial systems: beyond standards and templates
26:00 – Why most HMI screens are outdated and how to improve them
30:00 – Using consumer design trends in industrial HMI development
33:00 – Ownership vs. partnership: the evolving role of integrators
36:00 – Visualization tools: what's working and what still needs to improve
40:00 – Data in manufacturing: planning, silos, and interoperability
45:00 – Why planning trumps tools and how to avoid duplicate systems
49:00 – Real talk on end user responsibility and integrator lock-in
54:00 – How local integrators can thrive in a reshoring environment
57:30 – Early signs and implications of reshoring in manufacturing
01:01:00 – Introducing Abelara: Dylan and Glenn’s new consulting venture
01:04:00 – Book recommendation: Silos, Politics and Turf Wars
01:06:00 – Career advice for new engineers: learn by doing
01:09:00 – 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.com
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