Manufacturing Hub

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.

Welcome back to a special Thursday edition of Manufacturing Hub!In this episode, we dive deep into one of the standout presentations from the Prove It conference — featuring Travis Cox from Inductive Automation and Arlen Nipper from Cirrus Link Solutions.🎥 We start by reflecting on the Prove It showcase, where Travis and Arlen demonstrated the power of Unified Namespace (UNS) and MQTT across every layer of the solution stack — from Edge devices, to the Ignition Gateway, to the Cloud.➡️ Watch as we discuss their approach to scalability, ease of deployment, and why Ignition continues to lead the way in industrial digital infrastructure.During the show, we cover:✅ The real-world adoption of MQTT vs OPC UA in manufacturing environments, and why OPC UA is still dominant in many industries.✅ Why naming conventions and early standardization are critical for successful UNS architectures.✅ How to tackle data contextualization and overcome the "tech debt" so common in brownfield facilities.✅ The importance of leadership-driven digital transformation and true IT/OT convergence.✅ Why future-ready architectures require blending traditional technologies like OPC UA with MQTT and open standards.✅ Insights into how small, medium, and enterprise manufacturers should approach digital transformation differently.Travis shares incredible insights on:🔹 The evolution of Ignition and its role as an IIoT platform🔹 Why a common digital infrastructure is non-negotiable for scaling🔹 How even small wins (like energy monitoring) can spark major cultural shifts in manufacturing organizations🔹 The growing role of IT leaders in successful plant floor modernization efforts🔹 How AI, ML, and advanced analytics will shape the future of real-time industrial operationsWe also dive into broader industry trends seen at Prove It, including how other platforms like Frameworks (Tatsoft) and WinCC OA (Siemens) position themselves in the evolving digital manufacturing landscape.Helpful Links: 🔗 Learn more about Inductive Automation: https://inductiveautomation.com🔗 Manufacturing Hub Podcast Archives: https://manufacturinghub.liveTimestamps: 0:00 - Intro and Prove It Recap5:30 - First impressions of the Inductive Automation session11:50 - MQTT vs OPC UA in real-world manufacturing18:10 - Challenges of UNS deployment and the importance of standards28:40 - IT/OT convergence and building unified teams38:20 - What sparks digital transformation success?47:10 - How Ignition fits into modern industrial architectures55:00 - Closing thoughts on Prove It and the future of manufacturing🔔 Subscribe for more conversations on industrial automation, digital transformation, and manufacturing leadership every week!

In Episode 204 of Manufacturing Hub, we wrap up our month-long ERP series with Glenn from Waites. Glenn shares a practical framework for understanding ERP systems—perfect for engineers, plant managers, and anyone who’s struggled with clunky ERP software. We break down key modules like Financials, Supply Chain, MES, and Asset Management, and explore how modern tools are reshaping ERP usability.🔹 What You’ll Learn:Glenn’s 3-part ERP mental model: Master Data, Transactions, WorkflowThe difference between push vs. pull supply chain systems (MRP vs. Lean)Why gross margin is the #1 financial metric you need to watchHow MES and condition monitoring tools integrate with ERPPractical advice for engineers navigating digital transformation & MBAs💡 Perfect for anyone struggling to make sense of their ERP, or looking to modernize their stack without losing their sanity.📘 Recommended Reading: Lessons in Industrial Instrumentation by Tony Kuphaldt – Free online technical resource👤 Guest: Glenn – Chief Product Officer at Waites and co-founder of a new digital transformation consultancy with Dylan Dufrene🛠️ Sponsored by Talan Experts in ERP integration across SAP, Microsoft Dynamics, and Oracle Learn more: https://www.talan.com Catch Elvis from Talan in Episode 199📌 Watch all ERP Month episodes: 199, 201, 203, 204 🔔 Don’t forget to Like, Subscribe & Hit the Bell!#ERP #Manufacturing #MES #DigitalTransformation #IndustrialAutomation #ManufacturingHub #EngineeringLeadership #SCADA #PlantOperations #Waites #Talan******Connect with UsVlad RomanovDave GriffithManufacturing HubSolisPLCJoltek

In this episode, Dave and Vlad are joined by Jay and RJ from Total ETO to explore the often overlooked world of ERP for machine builders and systems integrators. While ERP conversations often focus on large-scale deployments like SAP or Oracle, this episode dives into the day-to-day of smaller, engineer-to-order (ETO) businesses—where spreadsheets still reign and project complexity is high.Jay and RJ share their unique perspectives—Jay coming from 25 years in automation and becoming a Total ETO user-turned-employee, and RJ bringing three decades of software expertise focused specifically on this niche. Together, they break down:The unique ERP needs of custom machine builders and SIsWhy project-based workflows don't fit traditional manufacturing ERPsCommon pitfalls like spreadsheet reliance and change order chaosThe difference between machine builders and system integrators (and how ERP can serve both)How they approach implementation in 4–6 months, not 4–6 yearsWhy people who've used Total ETO often end up joining the companyWhether you're managing projects off scratch paper or already in the market for your first ERP, this episode is full of insights on how to bring structure and visibility to custom manufacturing.💡 Key Topics[00:02:00] Intro to Total ETO and backgrounds of Jay and RJ[00:12:00] The life of a machine builder: high variability, custom BOMs, and the project-first mindset[00:22:00] Why most ETO businesses still run on spreadsheets[00:31:00] The emotional journey from ERP user to ERP evangelist[00:39:00] System integrators vs. machine builders: similar goals, different workflows[00:47:00] Why one-size-fits-all ERP fails for custom equipment manufacturing[00:58:00] Getting buy-in for ERP: from small teams to company-wide rollouts[01:07:00] Implementation: how Total ETO does it in under 6 months[01:18:00] Integration with CAD tools like SolidWorks and Inventor[01:26:00] The future: AI, web platforms, and the changing face of manufacturing software🧠 Memorable Quotes“Spreadsheets give me nightmares. That’s the main thing.” – Jay“Nothing gets done accidentally. You have to make ERP implementation a priority.” – RJ“We’re often a company’s first ERP—and we aim to be their last.” – RJ“Everything in ETO is dynamic. It’s not static like mass production. And your ERP needs to reflect that.” – Jay📚 Book & Content Recommendation📰 Automation AMA – The Automation Navigator by Sean DotsonRecommended by both Jay and RJ as an insightful, down-to-earth read for automation professionals.🎉 ShoutoutsThanks to TALAN for sponsoring this month’s ERP theme!And a special mention to Taylor Dykstra for supporting Total ETO at ProMat this week!******Connect with UsVlad RomanovDave GriffithManufacturing HubSolisPLCJoltek

What does it take to move from automation hype to practical, scalable solutions on the factory floor?In this deep-dive episode of Manufacturing Hub, recorded live at the ProveIt Conference, we’re joined by Benson Hougland, Vice President at Opto 22—a company that has been quietly shaping the future of industrial automation for over 50 years.Benson walks us through the journey of Opto 22: from its roots as the birthplace of the solid-state relay to becoming a leader in edge-native control platforms with the groov EPIC and groov RIO product lines. More importantly, he reveals how Opto 22 is tackling two of the most critical challenges in modern manufacturing: democratizing OT data and cybersecurity at the edge.We cover:✅ Who Opto 22 really is and what they set out to "prove" at the ProveIt Conference✅ The role of the Unified Namespace (UNS) in enabling real-time industrial data architecture✅ How Opto’s platforms help solve the "dark asset" problem in brownfield facilities✅ Cybersecurity by design—not just bolted on later✅ Why the controller of the future is more like a smartphone than a flip phone✅ Running containers on the edge: what this unlocks for OT teams✅ Long-term partnerships with companies like Inductive Automation and why that matters✅ How Opto 22 systems remain IT-friendly, OT-usable, and fully made in the USA✅ Their collaboration with the State of Indiana to bring energy-focused digital transformation to SMB manufacturers✅ Lessons from past moonshots—like cellular control systems with Nokia that were ahead of their time✅ What’s next: ML at the edge, scalable architectures, and more accessible solutions for plants without big digital teamsThroughout the conversation, Benson emphasizes a philosophy that will resonate with anyone trying to lead transformation in manufacturing: start small, solve a real problem, and scale with purpose. Whether you're tackling legacy infrastructure, looking to secure your OT layer, or just trying to make sense of the noise in the automation space, this episode will leave you with tangible ideas and a clear-eyed view of what's possible.🎧 Plus: Why PLCs need to behave more like clients, why MQTT is so central to modern architectures, and how to get buy-in from leadership with energy wins.******Connect with UsVlad RomanovDave GriffithManufacturing HubSolisPLCJoltek

In Episode 201 of Manufacturing Hub, we sit down with Tim Brown, a veteran leader with over 40 years of experience across manufacturing, construction, and IT. From managing massive ERP transformations to navigating global M&A integrations, Tim shares a masterclass in how to make enterprise software actually work in complex industrial environments.We cover everything from:What it was like managing ERP during Y2KThe critical difference between push vs. pull drivers for ERP changeHow mergers and acquisitions shape ERP strategyWhy “people problems” derail ERP more than technology ever doesReal tactics for managing global rollouts (including Japan, France, Canada, and the U.S.)His take on embedded AI in ERP platforms (and where it's really going)Governance, risk, and how to actually drive adoptionWhether you’re an IT leader, plant manager, systems integrator, or just ERP-curious — this episode offers real-world lessons and practical guidance from someone who’s done it all.🔹 Thank you to this month’s sponsor: TALANHelping manufacturers navigate ERP adoption, migration, and integration across SAP, Microsoft Dynamics, Oracle, and more. Meet them at the American Manufacturing Summit in Chicago on March 19–20, or visit their site to learn more.👇 Drop your questions or share your ERP war stories in the comments — we’d love to hear from you!📌 Chapters 0:00 Intro4:00 Tim’s Background & ERP Journey9:00 Y2K & Early ERP Lessons15:00 ERP Triggers: Push vs. Pull22:00 M&A Integrations: How It Actually Happens30:00 Roadblocks: People, Culture, and “We’re Special” Syndrome40:00 Standardization vs. Flexibility in Rollouts48:00 ERP Selection: Process, Partners, and Politics58:00 Risk Mitigation & Change Management1:05:00 MES, Data Ownership & Operational Autonomy1:18:00 AI & the Future of ERP1:25:00 Career Advice from Tim1:30:00 Final Thoughts & Book Recommendation🎧 Listen to Episode 199 with Elvis (Talen) for more on ERP selection👉 https://youtu.be/YOUR-LINK-HERE🔗 Follow us on LinkedIn📬 Never miss an episode — subscribe to the podcast on your favorite platform!******Connect with UsVlad RomanovDave GriffithManufacturing HubSolisPLCJoltek

In this episode recorded live at the ProveIt Conference, we sit down with Mark and Harry from Tatsoft, creators of the industrial IIoT platform Frameworks. We dive deep into how Tatsoft is redefining what a true industrial platform should be — built from the ground up for the factory floor, yet scalable across the enterprise.Mark and Harry walk us through:Their platform’s positioning as a SCADA, HMI, MES, and IIoT toolbox — all in oneHow Frameworks handles real-time data, from connectivity (MQTT, OPC UA, SQL) to transformation and dynamic visualizationWhy the “extra I in IIoT” matters when building for industrial environmentsThe challenges of IT/OT integration, people gaps, and legacy systems — and how Tatsoft tackles them head-onA demo of their ProveIt solution, showing off auto-recognition of new assets, dynamic UI, and high-performance visualization across devicesWhether you’re an end user, system integrator, or OEM, this episode will help you understand how Tatsoft’s Frameworks V10 is enabling fast, scalable, and future-proof industrial applications — without compromise.🔗 Learn more about Tatsoft: https://www.tatsoft.com🎥 Live from the show floor at ProveIt 2025.📅 Watch Manufacturing Hub live every Wednesday at 4PM ET.******Connect with UsVlad RomanovDave GriffithManufacturing HubSolisPLCJoltek