Manufacturing Hub

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.

Chris Stevens and Annemarie Breu from Siemens discuss the future of manufacturing resilience at Automate 2025. They explore how digital twins and co-pilot tools can revolutionize processes, enabling manufacturers to adapt to disruptions like supply chain shocks. Chris emphasizes the importance of empowering teams to take ownership of solutions, while Annemarie highlights the necessity of scaling technology for measurable outcomes. Together, they illustrate how Siemens is helping businesses transition from pilot projects to large-scale digital adoption, enhancing overall competitiveness.

Explore the world of manufacturing intelligence as hosts delve into data collection and energy monitoring successes. Hear about a transformative energy project at Procter & Gamble aimed at cutting power consumption by 20%. Discover the significant losses in pet food manufacturing due to poor batching and how precise data can salvage millions. The discussion also highlights the crucial role of AI in manufacturing while stressing the need for a strong data foundation. Career growth tips and insights inspired by Navy SEAL culture round out the conversation.

Caleb Eastman, an expert from Siemens with a focus on networking and automation, dives deep into the transformative potential of Machine Type Packages (MTP) and Machine Context Protocol (MCP) in modern manufacturing. He highlights how these technologies enable safe AI integration in factory settings. The discussion emphasizes overcoming resistance to change within manufacturing teams, the crucial role of organizational psychology, and practical steps to make digital transformation appealing to executives. It's a compelling look at the future of adaptable manufacturing.

In this engaging discussion, Bernd Raithel, Head of R&D for Siemens Factory Automation in the US, shares his expertise on evolving industrial control systems. He highlights the transition from legacy programmable logic controllers to software-defined automation, emphasizing the integration of AI and IT principles. Bernd explores the future of virtual PLCs and the significance of agile development in manufacturing. He also discusses how Siemens is making advanced tools accessible for smaller manufacturers, paving the way for digital transformation.

Jeroen Coussement, Founder and CEO of Factry, shares his expertise in modernizing industrial data architecture. He explains the transformative role of historians in manufacturing, detailing their evolution from simple data archiving to fulfilling key functions in data acquisition and modeling. Jeroen discusses cloud-native solutions and their adaptability across industries, emphasizing the need for a solid data foundation to enable advanced analytics tools. He highlights common digital transformation challenges and the importance of cohesive data strategies for improved decision-making.

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.