Manufacturing Hub

Siemens says a small manufacturer can start production optimization for $2,000 a year. Martin Valkysers and Flemming Kongsberg explain what that buys you.

Most digital transformation advice assumes a budget and an engineering bench most plants do not have. Flemming Kongsberg, who runs the SMB focus inside the Siemens CTO organization, discards the usual revenue and headcount definitions: an SMB is any manufacturer without the skills to absorb a complex digital change, and that includes some very large companies. He describes one customer running 900 devices across 17 locations where 90 percent of the machines are 30 years or older with zero...

David Nichols of Loupe explains what actually changed in automation engineering this year, and why control retrofits just got far cheaper.

Nearly twenty years into building high performance controls, David Nichols is blunt about what AI did to his business: what used to take six weeks now takes two, and his team ships roughly five times more software per sprint. An engineer dropped the raw documentation from a failing robotic cell into a folder, asked Claude for a state diagram, and got a reverse engineered flow chart in thirty minutes that beat anything the customer had. The...

Deglobalization is rewriting where factories get built, and Ujjwal Kumar of Siemens explains what has to change on the plant floor before reshoring actually works.

For thirty years the manufacturing playbook was labor arbitrage. Move high volume, low mix production to wherever disciplined labor was cheapest, then ship it back. Ujjwal Kumar, President of Automation for Siemens Digital Industries in the Americas, argues that model has quietly stopped making sense. Demand has fragmented into high mix, lower volume, regionally specific production, and the factories in Suzhou running on robots and autonomous systems no longer carry a cost...

After several weeks away from the podcast, Dave Griffith and Vladimir Romanov return to Manufacturing Hub to unpack their experiences at Automate 2026 and discuss what the event revealed about the current state of industrial automation.

Automate showcased an enormous range of robotics, industrial AI, machine vision, software, cloud connectivity, and emerging automation technology. However, some of the most revealing conversations were not about futuristic factories. They were about PLC 5 migrations, aging SLC systems, obsolete PanelView terminals, industrial networks, basic data collection, and how platforms such as Ignition actually connect to plant floor equipment.

Vlad shares...

Automate 2026 lands in Chicago next week, and Dave and Vlad break down how to work the show floor, where to network, and what to expect from their live booth demos.

Automate is the largest automation trade show in North America, and a four day event rewards preparation. Dave and Vlad share tactics refined over five years of attending together. The floor opens at 10:00 AM on Monday, and registration lines have swung from a five minute wait to nearly two hours, so arriving early matters. Monday morning and Thursday are the quietest days to reach specific vendors, while...

AI can finally write back to the plant floor, but only if you can trust it. Chris Stevens and Annemarie Breu of Siemens explain how orchestration makes that safe.

Industrial AI has reached a turning point. Manufacturers can already collect data, contextualize it, and surface insights, but the hardest step has always been turning insight into action on real control equipment. Chris Stevens and Annemarie Breu of Siemens explain how an orchestration layer finally closes that loop. Annemarie frames the tension clearly. Automation depends on determinism, while large language models are probabilistic by design, so the goal...

Industrial network protocols decide whether a machine talks or stays silent. Chuck from Horner Automation breaks down how they win, fade, and converge.

Chuck has spent 36 years at Horner Automation and lived through what the industry once called the fieldbus wars. Before Horner became known for its all in one controllers, it spent a decade building specialty IO modules for GE Fanuc during the era of DeviceNet, SDS, InterBus S, PROFIBUS, and CANopen. His core argument is that most of those early protocols were technically fine. The ones that became standards won on the commercial weight of...

Change management is the reason most manufacturing improvement projects quietly stall, even when the technical work is sound and the tools are right.

Vlad Romanov and Dave Griffith unpack their own change management war stories from across two decades in industrial automation. Vlad frames change management as understanding risk to the business and to every stakeholder, then putting the process in place that lets the organization absorb that risk. Technical feasibility is the easy half of any project. Getting humans to consistently work the new way is the half that wins or loses the budget.

...

Change management in manufacturing breaks down at the people layer, not the technology layer. This episode explains how engineering leaders actually drive adoption.

Ronald Sherrod is a Staff Automation Engineer at Regeneron deploying a global event based architecture and Unified Namespace rollout across pharmaceutical operations. Ron, Vlad Romanov, and Dave Griffith dig into the parts of change management that rarely make it onto vendor decks. Subscribe to Manufacturing Hub for weekly conversations with industrial automation practitioners.

Want to go deeper? Vlad and the team at Joltek have covered related topics here:
Digital Transformation in...

Inductive Automation cofounders Colby Clegg and Carl Gould go deep on the origins of Ignition, the road to 8.3, and what AI means for industrial automation.

Vlad and Dave host Colby Clegg, CEO, and Carl Gould, CTO, of Inductive Automation together for the first time to trace the full arc of the company. The story begins in 2003, when Sacramento systems integrator Steve Heckman brought Colby and Carl in to build the missing glue layer between OT data and modern IT tooling. What began as logging values into SQL databases became Factory PMI and eventually Ignition.

A...

Change management decides whether your MES or digital transformation project lasts, or quietly gets shut off six months after go live.

Vlad Romanov and Dave Griffith sit down with Logan Terry, who leads digital transformation at LSI, to dig into change management as the deciding factor in any automation or MES rollout. Logan defines change management as a methodical approach to moving an individual, team, or organization from a current state to a desired future state. The closer a system sits to where decisions are actually made, the more change management it requires, which is why MES...

Industrial AI is moving past the chatbot phase. From the Hannover Messe show floor to system integration workflows, here's what end users actually want now.

Vlad just returned from his first Hannover Messe, the largest industrial automation and manufacturing trade show in Europe. The takeaway that defined the week was a shift in how end users open conversations. A year ago, every booth visit started with the question, do you have AI? This year every vendor has some flavor of AI, so the question has flipped back to the one that actually matters. How does your product...

Digital twins and machine learning are redefining batch optimization in manufacturing. Learn how centerlining models can catch quality issues in real time before they become irreversible.

Concepts like digital twins, golden batch profiles, and statistical process control have long promised more than they delivered. Virag Vora of Twin Thread argues that layering machine learning on top of these ideas is what finally brings them to life. In this context, a digital twin is entirely data centric: a real time and historical representation of a process that serves as the foundation for AI models.

Physical AI is arriving on factory floors ahead of schedule, and Vention is already deploying it on applications four automation integrators failed to crack.

François Giguère, CTO of Vention, draws a precise line between agentic AI and physical AI. Agentic systems process data and return data. Physical AI controls motion and actuation that produce real world consequences on a factory floor where a hundred percent uptime is the only acceptable standard. Giguère has spent a decade helping build Vention, a platform that lets manufacturers design robotic cells in 3D, program them through natural language, sim...

AI in manufacturing is no longer a strategy reserved for the boardroom. It is a tool for the technician on the plant floor, and the results are already showing up in real operations worldwide.

Most digital transformation strategies in manufacturing are built for desk workers on the carpeted side of the building, not the operators and technicians keeping production running on the concrete floor. AI platforms have historically been designed for white collar knowledge workers with time to navigate complex systems, leaving the frontline worker as an afterthought. Nick Haase recognized this gap when building MaintainX in 2018...

Industrial AI is getting a lot of attention in manufacturing right now, but one of the biggest questions is still the most practical one. How do you turn plant data, process knowledge, and operational constraints into something that actually creates value? In this episode of Manufacturing Hub, Vlad Romanov and Dave Griffith sit down with Konstantin Paradizov of Eukodyne for a detailed conversation on what industrial AI looks like when it is applied by people who understand manufacturing, MES, process improvement, data architecture, and the realities of the plant floor.

What makes this discussion especially valuable is...

Manufacturing Hub is back with Episode 252, where co hosts Vlad Romanov and Dave Griffith break down what an AI survival guide should actually look like for manufacturing and industrial automation professionals. This is not a hype conversation about replacing people with magic software. It is a grounded discussion about what AI tools can do today, where they fail, why context and data quality matter so much, and how industrial teams should think about experimentation without losing sight of real operating constraints.

In this episode, Vlad and Dave unpack the evolution many engineers and technical leaders have already...

In this episode of Manufacturing Hub, Vlad and Dave sit down with Travis Cox and Kevin McCluskey from Inductive Automation to unpack what was actually proven at ProveIt and why it matters for teams trying to modernize plants without building a fragile mess of point to point integrations. If you have ever looked at a shiny demo and wondered what the real architecture looks like, how it scales beyond a single line, and what it takes to roll out across multiple sites without turning every change into a high risk event, this conversation is for you.

Travis...

This episode wraps up our Technology Modernization theme with a Siemens perspective that feels very grounded in what factories are actually dealing with right now. Brian Albrecht and Louis Hughes from the Siemens XD team walk through what they are seeing in the field across brownfield and greenfield conversations, why executives keep asking for industrial AI before the foundations are ready, and what it really takes to turn messy plant data into something you can trust for analytics, operations, and eventually AI enabled workflows.

A big thread in this conversation is that modern manufacturing is not blocked...

In this special ProveIt edition of Manufacturing Hub, Vlad Romanoff and Dave Griffith sit down with Amy Williams from Skellig Automation to unpack Enterprise C, a life sciences virtual factory built to look and feel like the reality inside many regulated facilities today. If you work around batch processes, compliance, historian projects, electronic batch records, or industrial data architecture, this conversation is a practical walkthrough of what it actually takes to turn raw signals into a story you can defend, improve, and scale.

Amy has spent years working exclusively in life sciences manufacturing, starting deep in DeltaV...

In this episode of Manufacturing Hub, Vlad Romanov and Dave Griffith sit down with David for a practical, operator grounded conversation about industrial data, modernization, and what it actually takes to turn plant floor signals into business decisions. David has spent more than two decades in manufacturing across automotive, solar, and electric vehicles, and his story is a familiar one for a lot of us. He walked into a plant thinking he was there for a project, discovered PLCs in real time, and never left the factory world. From early days wiring up a SQL Server to pull line...

In this episode of Manufacturing Hub, Vlad Romanov and Dave Griffith sit down with Benson Hougland from Opto 22 to get brutally practical about what is actually running on shop floors today, and what it takes to move from legacy automation to modern, data ready operations without breaking what already works. If you have ever walked into a plant and seen a mix of decades old controllers, manual processes, islands of automation, and a few shiny modern pockets of connectivity, this conversation will feel very familiar. Benson has spent roughly three decades at Opto 22 and he has seen the full...

Technology modernization in manufacturing is not a list of shiny tools. It is a sequencing problem. In this episode of Manufacturing Hub, Vlad Romanov and Dave Griffith break down why the executive vision for AI often collides with the reality of the plant floor, and what a practical path forward actually looks like when you account for data quality, legacy controls, networking, and the true cost of integration.

A core theme in this conversation is imperfect information. Leaders often believe the data already exists because reports exist. But a stack of paper, a few spreadsheets, or a...

In this episode of Manufacturing Hub, hosts Vlad Romanov and Dave Griffith welcome back Amos Purdy for a wide ranging conversation that connects plant floor reality with SCADA, MES, and the business decisions that actually fund modernization. Amos shares his path from early software and programming work into industrial automation, including building an industrial automation class and lab, leading MES and SCADA efforts, and working across industries where the pace, constraints, and validation expectations can feel like completely different worlds. If you have ever wondered why a solution that looks obvious on a whiteboard takes months or years to...

Welcome to Manufacturing Hub and welcome to 2026. In this kickoff episode, Vlad Romanov and Dave Griffith reset the table for the year and share what the show is really about: practical conversations with people who build, run, secure, and modernize manufacturing systems. If you are new here, this is the perfect starting point because we explain the format, the monthly themes, and the reason we keep coming back to the same hard truth: manufacturing improvement is never just about technology. It is also about people, process, incentives, and change.

From there, we get into the big question...

Handing over a project is one of the most underestimated and misunderstood phases in manufacturing and industrial automation. In this episode of Manufacturing Hub, Vlad and Dave sit down to break apart real stories from the field covering MES rollouts, line commissioning, SCADA and ignition development, operational adoption, and the very real consequences of poor knowledge transfer. Most conversations online focus on the technical build, but very few people emphasize the point where engineering lets go and the operations team becomes the true owner of the system. This episode brings forward examples of both well executed handovers and catastrophic...

This episode takes you inside the reality of becoming a systems integrator and growing a technical services business from the ground up. Vlad and Dave share their personal experiences launching and running integration companies, the lessons they learned as engineers moving into business ownership, and the challenges that come with finding customers, choosing technologies, setting rates, managing cashflow, and hiring the right people. This is a detailed and candid look at what the journey actually requires. It is also a practical conversation that breaks down how technical professionals can evolve beyond pure engineering work in order to build a...

In this conversation recorded at the Ignition Community Conference, Vlad, Dave, and their guest David Grussenmeyer from Inductive Automation explore one of the most important and inspiring stories in the world of industrial automation education. David leads the Educational Engagement Program at Inductive Automation and has spent the last several years building a global network of universities, colleges, students, and integrators who are working together to bridge the gap between academic theory and real world industrial skills. This episode provides a detailed look at how the Student Buildathon was created, how it works, why it matters, and what it...

In this episode of Manufacturing Hub, hosts Vladimir Romanov and Dave Griffith sit down with Davide (David) Pascucci, founder of Bright IA (https://brightiatx.com/), for an in-depth conversation about what it truly takes to build, grow, and succeed in the world of robotics integration and industrial automation.

Davide shares his incredible journey from Italy’s oil and gas sector to leading one of Texas’s most promising automation firms. His story highlights the reality of moving from traditional controls work to full-scale robotics integration. Listeners will learn how his company evolved from small local projects into comp...

At Automate 2025, Vlad and Dave take Manufacturing Hub inside the Siemens booth to explore how one of the world’s largest industrial technology companies is shaping the future of manufacturing. From the latest S7-1200 G2 PLC to industrial copilots powered by AI, digital twins that simulate entire factories, and virtual PLCs redefining automation, this episode is packed with insights from Siemens leaders and engineers.

In this conversation series, we uncover the evolution of hardware, software, and data-driven manufacturing with experts including Chris Stevens and Anna-Marie Breu on customer experience and digital twins, Bernd Raithel on software-defined au...

Modern robotic picking is moving beyond neat rows and perfect lighting conditions. In this Automate 2025 conversation, Vlad and Dave sit down with Kevin Wu from Siemens to explore how Simatic Robot Pick AI Pro is tackling the messy reality of warehouses and factories. They discuss how the new edge architecture with the Simatic IPC BX 59 A and an NVIDIA GPU lifts pick rates to well over one thousand picks per hour, why multiple suction patterns matter for stability on large or flexible items, how camera agnostic support opens the door to new vision hardware, and why transparent objects are...

ICC 2025 was a clear level up for the Ignition community. In this conversation Vlad and Dave share on the ground insights from a week of packed sessions, vendor showcases, and ProveIt demonstrations that brought working integrations to life. They unpack why the move to a larger venue created more chances for deep technical conversations, how the community benefited from hands on demos that connected to a shared data backbone, and what record attendance means for the growth of modern SCADA and manufacturing data platforms. The episode then shifts into a focused discussion with Travis Cox from Inductive Automation on...

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...

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...

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...

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...

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...

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 tu...

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 sh...

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.