Manufacturing Hub

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.

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