Unplugged: An IIoT Podcast

This episode is brought to you by Cirrus Link Solutions and Canary Labs.

Cirrus Link Solutions - MQTT and Sparkplug software that connects OT to IT and cloud systems.

Learn more: https://unpluggediiot.com/go/cirrus-link

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Can an industrial PC really replace a PLC?

Jake Abel, P.E., Principal Automation Engineer at Edgenaut, spent more than a decade programming PLCs and commissioning oil and gas equipment before moving into virtual PLCs at OTee. He joins Phil...

This episode is brought to you by Canary Labs, and Cirrus Link Solutions.

Canary Labs - The industrial historian platform that captures your plant and process data the moment it is generated and makes it instantly accessible across your entire operation.

Learn more: https://unpluggediiot.com/go/canary-labs

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Node-RED is running in factories, renewable energy systems and smart buildings all over the world. Most of the industry has no idea who built the protocol packages that made it production-worthy.

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This episode is brought to you by Cirrus Link Solutions and Canary Labs.

Cirrus Link: https://unpluggediiot.com/go/cirrus-link

Canary Labs: https://unpluggediiot.com/go/canary-labs

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Arlen Nipper — MQTT co-inventor and President & CTO of Cirrus Link Solutions — returns for his third appearance on Unplugged.

Twenty-five years after co-inventing MQTT to connect an oil pipeline over a satellite link in the Middle East, Arlen walks through the current state of the protocol: 15 million tags in a single deployment at mill...

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This episode is brought to you by Canary Labs, and Cirrus Link.

Canary Labs — The industrial historian platform that captures your plant and process data the moment it's generated and makes it instantly accessible across your entire operation.

Learn more: https://unpluggediiot.com/go/canary-labs

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Phil Seboa and Ed Fuentes sit down with Kyle Van Eenennaam (BW Design Group) to explore what it actually looks like to work at every level of the Ignition ecosystem.

Phil Seboa and Ed Fuentes sit down with David Ariens (Analytics For Industry / AVEVA) and Willem van Lammeren (Syensqo) to explore why IT/OT convergence fails — and what organisations actually get right when convergence works.

They discuss the cultural and technical silos that keep IT and OT teams divided, common misconceptions on both sides, and the practical changes that make integration stick in industrial environments.

Topics covered:

• Why convergence projects stall or fail

• Breaking silos without burning bridges

• What good IT/OT integration looks li...

What changes when the assets you operate stop being centralised and predictable, and start being distributed, intermittent and weather-dependent? The old operations playbook breaks — and most digital programmes are still designed for the old one.

Dr Hema Wadhwa, Associate, Data & Analytics | Asset Management and Performance at Aurecon, joins Phil Seboa and Ed Fuentes to talk about building digital asset intelligence for the energy transition. Hema's career is a live map of that transition: she started as a Floating Systems Engineer in global oil and gas, moved through subsea engineering and power generation operations, and now leads digital st...

Every IIoT project starts the same way: you need data out of a PLC. The standard answer is OPC-UA — but what if that protocol is overloading your PLCs, eating bandwidth, and costing you thousands in upsized hardware?

In this episode, Christofer Dutz — creator of Apache PLC4X and CEO of ToddySoft GmbH — joins Phil Seboa and Ed Fuentes to explain why speaking the native tongue of your PLCs is faster, cheaper, and more efficient than wrapping everything in OPC-UA. Chris shares how PLC4X pulled 2,600 data points every 200 milliseconds at just 2–3% CPU overhead — compared to OPC-UA choking at 200 dat...

In the final part of our FlowFuse mini-series on Unplugged: An IIoT Podcast, Phil Seboa and Ed Fuentes close out with Kristopher Sandoval of FlowFuse on what happens once you can build fast: how do you scale, govern and standardise industrial applications across plants, lines and teams?

Kristopher explains why Expert doesn't replace developers — it removes repetitive setup so engineers can focus on operational problems, business logic, architecture and deployment strategy. We cover scaling via FlowFuse pipelines (build once, roll out to hundreds of devices), granular RBAC that persists across instances and sites, air-gapping and data sovereignty fo...

In Part 2 of our FlowFuse mini-series on Unplugged: An IIoT Podcast, Phil Seboa and Ed Fuentes get practical with Kristopher Sandoval from FlowFuse. We move from “what is the application gap?” to what it looks like to close it on the shop floor.

Kristopher walks through real operational use cases—OEE dashboards, shift handover workflows, quality validation, and asset monitoring—starting with the operational problem and then showing the working application. We also dig into the technical mechanics: how FlowFuse Expert turns plain-language requirements into Node-RED nodes and flows, updates to the immersive editor in FlowFuse 2.30, and the gove...

In this first episode of a 3-part FlowFuse mini-series on Unplugged: An IIoT Podcast, hosts Phil Seboa and Ed Fuentes sit down with Kristopher Sandoval of FlowFuse to unpack the application gap in industrial operations — the growing distance between how many applications industrial teams need and how fast their developers can build them.

Kristopher explains why so many operational workflows still live in spreadsheets, local scripts and one-off dashboards, and how the Node-RED → FlowFuse → FlowFuse Expert stack is changing the equation. We cover what FlowFuse Expert actually is — an AI co-pilot that builds industrial applications on a Node-RED...

What does it take for AI to actually deliver on the factory floor? In this episode, we explore why most manufacturing AI pilots never make it to production, and what changes when you get the data architecture right.

Francisco Almada Lobo, CEO and Co-Founder at Critical Manufacturing, joins Phil Seboa and Ed Fuentes to discuss MES as the foundation for manufacturing AI, why context beats compute, and what regulated industries need before they can trust AI in production.

Key topics in this episode:

Howard Sachs joins Phil Seboa and Ed Fuentes to discuss how de-risking industrial technology, championing sovereign manufacturing, and first-principles leadership are shaping Australia's industrial future.

Key topics in this episode:

Connect with Howard on LinkedIn: https://www.linkedin.com/in/hsachs/

Connect with Phil on LinkedIn: https://www.linkedin.com/in/philseboa/

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Most industrial AI projects fail before they produce anything useful. The models are ready, the dashboards look great, and the executive presentation landed. But on the shop floor, nobody can get clean data out of the PLC without calling the vendor. The missing piece is a data foundation.

Alexander Kruger, co-founder and CEO of United Manufacturing Hub (UMH), joins Phil Seboa and Ed Fuentes on this episode, powered by PLCnext Technology, to explain why factory AI stalls without the right infrastructure underneath it, why boring technology beats shiny platforms, and how open source tooling is putting data...

Most industrial data projects fail before they start. The data is clean, the tools are connected, and the dashboards look great. But nobody can explain why the production line dropped 12% last Tuesday. The missing piece is human context.

Bob van de Kuilen, CEO and co-founder of Thred, joins Phil Seboa to explain why knowledge graphs fill the gap that the Unified Namespace leaves open, and how pairing them with AI turns weeks of troubleshooting into minutes.

Key topics in this episode:

Containerization is quietly reshaping how factories deploy and manage software, but most OT teams never asked for it. In this episode powered by PLCnext Technology, we explore why containers matter for manufacturing and how to adopt them without the complexity.

Neil Cresswell, Founder and CEO of Portainer, joins Phil Seboa and Ed Fuentes to discuss how his platform went from an IT tool to a factory floor essential, and why the technology behind it should be invisible to the people using it.

Key topics in this episode:

Carl Gould, CTO and co-founder of Inductive Automation, joins hosts Phil Seboa and Ed Fuentes for an in-person conversation recorded in Australia ahead of the Ignition Everywhere event in Brisbane.

Carl traces Ignition's journey from FactorySQL in 2003 to the 8.3 release, which introduces file-based configuration, Git and GitOps compatibility, Perspective offline mode, and a new architecture for managing distributed OT systems at scale. He breaks down the three design principles that have guided the platform from day one (cost, convenience, and capability), shares his evolving take on AI in industrial automation, and explains why he calls the IT...

What happens when a controls engineer raised in coal mines starts turning chicken manure into renewable energy? In this episode, made possible by PLCnext Technology, we get a masterclass in practical automation, functional safety, and building systems that work in the real world.

Jason Watts, Owner and Founder of Alpha Industrial Technologies, joins Phil Seboa and Ed Fuentes to discuss building an automation company around passionate engineers, using AI as an adversary in the design process, and why improperly applied safety functions can be more dangerous than no safety at all.

In...

Join host Ed and Phil as they explore how PLCnext Technology is redefining what industrial controllers can do, and why openness in automation is both a massive opportunity and a serious responsibility. Martin Boers, Technical Specialist at PLCnext Technology with Phoenix Contact, joins to discuss the origins of the PLCnext ecosystem, what IT/OT convergence really looks like on the plant floor, and how partnerships with companies like Festo and Yaskawa are shaping the future of automation platforms.

Key topics in this episode:

- The four pillars of PLCnext Technology: Control, Engineer...

What happens when a controls engineer with 16 years of mining and manufacturing experience decides to build an AI-powered SoftPLC from scratch? In this episode, we find out.

Alex Sharikov, Founder of JasperX and creator of JasperNode, joins Phil Seboa and Ed Fuentes to share how he's enabling small manufacturers to program and troubleshoot their control systems using plain English, no PLC software required.

Key topics in this episode:

Industrial automation meets modern software as FlowFuse CEO ZJ van de Weg joins Phil Seboa and Ed Fuentes to unpack how open-source tools like Node-RED are connecting teams across IT and OT, breaking down barriers with visual, low-code programming. Hear firsthand insights about scaling automation systems, the challenges and rewards of open source in manufacturing, and clever approaches to secure data management and fleet updates.

From home automation passion projects to strategic deployment in factories, this episode teases out the evolution of workflow integration, the importance of context, and practical ways organizations are pursuing smarter operations, plus...

In this episode of Unplugged, powered by PLCnext Technology, Phil and Ed they sit down with Jasper Louage of Mustry Solutions to discuss the latest advances in industrial automation and manufacturing data systems. Jasper shares his experience bringing event-driven architectures, open source platforms, and unified namespace concepts to real-world manufacturing environments. Hear about practical integrations, data flow from plant floor to enterprise, and managing change in IT/OT cultures. Whether you're a manufacturer, tech professional, or automation enthusiast, you'll gain perspective on BI, MES, SCADA, open source, and the future of industrial technology.

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This...

In this week's episode, powered by PLCnext Technology, Cisco's Chief Global Architect Kevin Wood joins the conversation to break down the practical strategies manufacturers need for secure, future-ready operations. Hear firsthand about the real-world challenges holding back IT and OT collaboration, the critical importance of visibility for protecting and optimizing your plant floor, and the evolving role of network infrastructure in enabling Industry 4.0.

If your organization is navigating legacy technology, security risks, or planning large-scale digital transformation, this episode is packed with expert guidance and industry best practices. Walk away with actionable steps for building a resilient...

Decades of industrial automation, SCADA implementations, and digital transformation meet the future of IIoT in this conversation with special guest Max Carritt, made possible by PLCnext Technology. Hosts Phil Seboa and Ed Fuentes trace Max’s journey from early experiences in Texas gas plants to leading multi-site SCADA modernization in Europe.

This episode covers technical growth, project challenges, cultural contrasts between U.S. and European automation, and hands-on learning with open platforms like Ignition. Highlights include mobile SCADA innovations, transitioning to enterprise-scale solutions, best practices for reducing tech debt, and building custom applications for fun (like D&D...

IT and OT have never been closer yet more misunderstood. In this episode, powered by PLCnext Technology, David Ariens brings candid insight from his global industry experience to the table, breaking down why IT/OT convergence remains a challenge and how it’s far more than just a technical problem. Hear stories from frontline operations, learn why trust and collaboration trump technology, and get practical advice for companies wrestling with digital transformation across manufacturing, infrastructure, and process sectors.

From lessons in organizational models to thoughts on data openness, the conversation uncovers strategies for building real momentum behind ch...

In this episode of Unplugged, powered by PLCnext Technology, Phil Seboa and Ed Fuentes sit down with Matt Barber, a globally respected MES specialist at Infor, to break down the evolving world of Manufacturing Execution Systems.

Matt explains what MES is, how it has grown into the broader framework of Manufacturing Operations Management, and why these systems have become essential for modern manufacturers. He covers the practical benefits, including real-time data visibility, stronger quality control, and reduced waste across production environments.

The conversation also explores the real challenges companies face when adopting MES. Matt emphasizes...

Get a firsthand look into the heart of Australian manufacturing as hosts Phil Seboa and Ed Fuentes sit down with Shane Williams and Paul Mason, two prominent voices from the Manufacturing Tech Australia Podcast. This episode examines the practical sides of digital transformation—beyond the buzzwords—to the real drivers, pain points, and breakthrough strategies shaping factories across the country.

Listen in as the group compares IT and OT perspectives, highlights the evolving role of data, addresses challenges with legacy systems, and discusses how Australian businesses are tackling integration, culture, and rapid technological change. Candid stories from the...

Hans Schrynemakers joins hosts Phil Seboa and Ed Fuentes to discuss his journey from frustrated nights on the factory floor to becoming an advocate for structured, modular PLC programming. Hans brings over 20 years of automation experience, sharing hard-earned knowledge on building scalable, maintainable industrial applications. The conversation spans practical strategies for naming conventions, documentation, and the role of comments, as well as his approach to training engineers worldwide. The episode also covers modernization projects, motion control, and the future of PLC programming in an AI-driven world.

About Hans:

Hans Schrynemakers has helped...

Phil and Ed sit down with Alex Sims, Technical Support Lead at Caliper. With a background as a qualified electrician and data technician, Alex offers a unique perspective on how practical trades experience can shape and refine IoT solutions for industrial and environmental challenges. The conversation uncovers practical stories from deploying climate sensors to protect bat colonies, managing connectivity in tough environments, and creating scalable, user-friendly IIoT products for real-world scenarios.

From tackling the steep learning curve of IoT as a tradie to overcoming industry-wide issues of scalability, integration, and support, Alex shares lessons learned on the...

Phil Seboa and Ed Fuentes sit down with Melvin Francis, a research-driven engineer and technical marketing leader at BE Services, for a packed conversation on the realities of real-time industrial automation, edge AI, and the technical leaps powering Industry 4.0. Melvin shares his hands-on journey from developing open-source real-time Ethernet protocols in India to driving innovation in Germany’s advanced manufacturing sector.

This episode covers the critical distinction between real-time performance and speed in OT environments, the impact of edge AI on traditional cloud models, and the emerging value of time-sensitive networking (TSN) for seamless in...

This special episode of Unplugged is brought to you by our sponsor, Inductive Automation and marks our first-ever in-person recording.

Join hosts Phil Seboa and Ed Fuentes as they sit down live with Colby Clegg, CEO of Inductive Automation, for an in-depth conversation on the future of industrial automation and the evolution of the Ignition platform.

Colby shares insights into the upcoming Ignition 8.3 release, a major milestone that wraps up a multi-year vision. The discussion explores powerful new features like source control, deployment modes, and event streaming, while diving into broader industry shifts like the...

Jan Madsen, founder of Enuda, shares his unique perspective on systems integration in Europe and what it means to build an Ignition-only team that bridges the gap between operations and finance.

Jan shares real stories from the plant floor, practical lessons from failed and successful projects, and why sticking to timeless business fundamentals outlasts chasing the latest tech trends. He shares insights on fostering a remote team of talented young engineers, the challenges and rewards of focusing solely on Ignition, the ongoing shift toward MQTT in industrial protocols, and why clear communication is often more valuable than...

Engineer, content creator, and IIoT educator, Zack Scriven, joins Phil and Ed for a wide-ranging discussion on the evolution of industrial digital transformation, the impact of authentic content creation, and the power of community.

Zack shares his story from being introduced to SCADA at a young age, to taking part in award-winning industry projects, to building one of the most recognized educational brands around Industry 4.0.

This episode covers the rise of the unified namespace, practical realities behind successful digital strategies, the importance of intuitive design in industrial systems, and the value of starting small when...

Matthew D. Smith, CEO of fieldcloud SAS, joins host Phil Seboa for an energetic and eye-opening episode focused on industrial connectivity, retro computing, and bridging cultural divides in global automation projects. With decades of experience in IT, SCADA, and telecoms, Matthew shares his background working on legacy systems at Eskom, inventive projects in the oil and gas sector, and the practical realities of deploying IIoT solutions in some of the world’s toughest environments. Learn how fieldcloud SAS approaches obsolescence, knowledge transfer, and the challenges of language and culture in international fieldwork.

Connect with Phil on LinkedIn:

Vladimir Romanov joins Phil Seboa to break down what it truly takes to shift legacy manufacturing systems into modern, data-driven operations. Bringing stories from the plant floor and insight from his time at ProveIt, Vlad reflects on the messy reality of automation upgrades, extracting meaningful data, and managing challenging change on both technical and human fronts. The episode. brought to you by our friends at Inductive Automation, goes beyond software hype, revealing the tough questions around ROI, assessing what to modernize, how to contextualize process data, and why education and buy-in matter more than the flashiest technology. Expect candid...

Brandon Artz joins Phil Seboa and Ed Fuentes for a wide-ranging conversation on the real-world challenges and opportunities shaping industrial automation and cybersecurity. From lessons learned bridging the divide between IT and OT teams, to candid stories about documentation mishaps, air-gapping missteps, and sticky financial roadblocks, Brandon’s hands-on perspective demystifies the complexities of smart manufacturing. Throughout the discussion, listeners will hear practical tips on proactive risk management, the impact of soft skills like communication and conflict resolution, and how cross-disciplinary curiosity fueled by everything from Linux tinkering to DIY AI at home can shape a successful career. Packed wi...

From the high-security demands of airports to the everyday comfort of smart homes, Alby Eckel shares his unique path from aviation industry specialist to founder of his own automation business. This episode uncovers what really happens behind the scenes in airport operations, the challenges of integrating legacy systems, and the opportunities IoT solutions are bringing to both large-scale infrastructure and Australian agriculture. Hear practical stories about predictive maintenance, data-driven farming, and how making technology approachable for end users, whether they're farmers or homeowners—is accelerating smarter, safer experiences. Insights on regulations, radio tech, and the shifting landscape of automation ma...

Join hosts Phil Seboa and Ed Fuentes as they sit down with Rafael Amaral, CTO and cofounder of TilliT. With decades of hands-on manufacturing and IT experience, Rafael shares his perspective on bridging the gap between the shop floor and digital tools. They examine the challenges manufacturers face in moving away from paperwork and spreadsheets, misconceptions around MES, and what it really takes to achieve user-friendly digital transformation.

Rafael discusses lessons learned from early MES projects, why operator-first design matters, and how making manufacturing systems simpler without losing capability is possible. The conversation covers effective strategies for...

In this episode of Unplugged, Phil Seboa and Ed Fuentes sit down with Jarith Fry, the SCADA and Systems Engineering Manager at Highland Pine Products. Jarith, an experienced engineer and innovator, shares his journey from Washington State, where he developed a passion for robotics inspired by his favorite superhero, Iron Man. Transitioning from integrator to end user, Jarith discusses the challenges and successes of modernizing equipment at Highland Pine, including moving from legacy systems to state-of-the-art technologies like Ignition. He also touches on the importance of community and training, security concerns, and innovative projects both at work and home...

In this special episode brought to you by Inductive Automation, hosts Phil Seboa and Ed Fuentes welcome back Arlen Nipper, a pioneer in the Industrial Internet of Things (IIOT) and co-inventor of MQTT. Arlen takes us on a deep dive into the latest advancements from Cirrus Link with a special focus and Unified Namespace (UNS) demo.

Discover how the UNS concept is transforming data management in industrial systems by providing a structured and scalable way to organize and access data. Arlen walks us through the new enhancements to the Cirrus Link portfolio, including the MQTT engine's ability...

In this episode brought to you by Inductive Automation, Phil Seboa sits down with Vice President of Opto22, Benson Hoagland. Benson brings his 30 years of experience in industrial automation and IoT to discuss the benefits of Ignition by Inductive Automation along with his intriguing journey into the world of automation and IoT. They also discuss the growth of home automation, the importance of interoperability, and their experiences from the recent ProveIt conference.

About Inductive Automation:

By cross-pollinating IT with SCADA technologies, Inductive Automation created Ignition software, the first universal industrial application platform...