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 hardware, switches, and cables? Is it the way new machines are integrated into existing plants? Or is it the broader strategy of ensuring that data, safety, and scalability are protected? The answer, as both Vlad and Dave explain, is that it is all of these at once.

Throughout the discussion, we explore real-world stories where poor architectural decisions led to unplanned downtime, cybersecurity risks, or expensive rework. Vlad shares an example of a palletizer brought online with unmanaged switches and insecure remote access hardware that nearly crippled production until it was properly segmented. Dave recalls his own field experiences, including unusual setups where integrators resorted to improvised remote troubleshooting, highlighting just how creative but fragile some solutions can be.

The episode also looks at the evolution of remote access. From the early days of Ewon boxes to modern expectations of secure VPNs, jump boxes, and approved engineering workstations, we discuss what role remote connectivity should play in today’s manufacturing environment. While these solutions can reduce travel time and speed up support, they can just as easily introduce vulnerabilities and trust issues if not carefully managed.

From there we move into the technical tradeoffs of device level ring versus star topologies. Vlad explains why he often prefers device level ring to save costs and simplify troubleshooting, while Dave weighs in on the importance of pre-molded cables, managed switches, and long-term maintainability. We also analyze example architectures from Rockwell white papers, pointing out where diagrams align with field best practices and where they differ from what engineers often see in real facilities.

Finally, we broaden the perspective by comparing greenfield and brownfield deployments. Greenfield projects allow prime contractors and consultants to design standards up front, but most facilities live in brownfield reality where years of technical debt, unmanaged switches, and ad hoc networks make improvements harder. We also touch on how architecture differs by industry, whether in food and beverage, pharmaceuticals, oil and gas, or distributed environments such as trains or pipelines.

The conversation closes with predictions, career advice, and resource recommendations. Vlad stresses that CCNA is still one of the best starting points for engineers who want to understand industrial networking fundamentals, and Dave emphasizes the importance of asking the right questions and learning from experienced peers. Both agree that demand for data, combined with the rise of AI, will continue to stress legacy networks until companies recognize the need for robust, standards-driven architectures.

If you work in automation, engineering, IT, or plant management, this episode will give you perspective on why network architecture is not just a technical afterthought but a strategic enabler of digital transformation.

Timestamps
00:00 Introduction and community updates
02:30 Defining architecture in manufacturing
05:00 Why networks are the backbone of manufacturing systems
08:00 A real-world palletizer story and the risks of unmanaged switches
14:00 The rise and pitfalls of remote access devices
18:30 Field story of unconventional remote troubleshooting setups
23:00 Who is responsible for network design: end users, integrators, or OEMs
28:00 Analyzing Rockwell’s reference architecture diagrams
36:00 Device level ring versus star topologies in practice
49:00 Brownfield versus greenfield considerations
56:00 Industry-specific architectures from food and beverage to oil and gas
01:04:00 The role of standards and corporate versus local decision making
01:08:30 Predictions, career advice, and recommended resources

References Mentioned in this Episode
Ignition Community Conference: https://icc.inductiveautomation.com/

Siemens SPS Atlanta Event: https://new.siemens.com/us/en/company/fairs-events/sps.html

Rockwell Automation Architectures and Design White Papers: https://literature.rockwellautomation.com

CISSP Official Study Guide: https://www.isc2.org/Certifications/CISSP

Winning by Tim Grover: https://www.amazon.com/Winning-Unforgiving-Race-Greatness/dp/1982168862

Cisco CCNA Certification: https://www.cisco.com/c/en/us/training-events/training-certifications/exams/current-list/ccna.html

About the Hosts

Vlad Romanov is an electrical engineer and consultant with over a decade of experience in manufacturing and industrial automation. His background spans global companies such as Procter & Gamble, Kraft Heinz, and Post Holdings, where he has led modernization projects, SCADA and MES deployments, and digital transformation initiatives. He is the founder of Joltek, a consulting firm helping manufacturers align people, process, and technology to improve operations, and he also leads SolisPLC, an education platform for automation professionals. Connect with Vlad on LinkedIn: https://www.linkedin.com/in/vladromanov

Dave Griffith is a manufacturing consultant and co-host of Manufacturing Hub. With extensive experience in controls, systems integration, and business development, Dave has helped manufacturers across industries adopt SCADA, MES, and digital transformation solutions. He frequently shares insights on IT-OT convergence, operational strategy, and leadership in the automation space. Connect with Dave on LinkedIn: https://www.linkedin.com/in/davegriffith

Joltek is a consulting and integration firm that helps manufacturers modernize with clarity, strategy, and execution. Built on decades of hands-on experience in engineering, automation, and plant leadership, Joltek bridges the gap between technical complexity and business value. The team is known for uncovering hidden risks in outdated systems, designing scalable IT and OT architectures, and guiding digital transformation initiatives that actually deliver measurable results. Whether it is upgrading control systems, deploying SCADA and MES platforms, or advising on strategic investments, Joltek consistently brings deep expertise and practical solutions that make manufacturing operations more resilient, efficient, and future ready.

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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.

Timestamps
00:00 Introduction and welcome with Dave, Vlad, and Kevin
02:00 Kevin’s background and entry into industrial software
05:00 Lessons from early HMI and integrator experiences
07:30 The importance of integrators in Inductive Automation’s go-to-market strategy
09:00 Transition into sales leadership and learnings from global customers
13:00 Ignition 8.3 beta release process and development challenges
18:00 Historian improvements and introduction of QuestDB
21:00 The new Siemens driver and why it matters globally
27:00 Use cases for multiple historians and large-scale data performance
31:00 Kafka integration, Event Streams, and IT-OT convergence
35:00 DevOps capabilities in Ignition including Git and deployment modes
41:00 Preview of the Ignition Community Conference and new venue
44:00 The Hub, CoLab, and community-driven sessions at ICC
50:00 Prove It sessions and exhibitor highlights
56:00 The Build-On competition and its evolution
01:01:00 Predicting the future of ICC and Ignition
01:03:00 Kevin’s career advice for engineers and integrators
01:05:00 How listeners can connect with Inductive Automation

References Mentioned in the Episode
Inductive Automation: https://inductiveautomation.com/

Ignition 8.3 Beta Release Notes: https://inductiveautomation.com/downloads/release-notes

QuestDB: 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 Hosts
Vlad 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 Guest
Kevin 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.

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 measurable business impact. Together, they outline how Siemens is helping manufacturers move from isolated pilots to large scale adoption, ultimately strengthening resilience and competitiveness in today’s uncertain environment.

We examine the meaning of manufacturing resilience in practice, including how to withstand supply chain shocks, tariffs, and workforce challenges. The discussion also covers workforce empowerment and the need to make manufacturing attractive again, not only by deploying advanced technologies but also by enabling teams to own solutions from the ground up.

A major theme is the role of the digital twin. Chris and Annemarie explain why starting in the virtual world is essential to validate designs, optimize processes, and minimize downtime risks. They address how digital twin adoption is becoming more accessible through as a service delivery models and collaborative environments where end users, system integrators, and technology providers all contribute.

We also look at the connection between copilot technologies and both operations and engineering. Natural language copilots are enabling operators to troubleshoot equipment quickly and engineers to interact with simulation environments more intuitively. This shift is accelerating adoption while reducing barriers to advanced tools.

Finally, the episode touches on automation lifecycle management, drawing parallels to product lifecycle management. By centralizing and version controlling automation artifacts such as PLC programs, HMI projects, and industrial edge applications, Siemens is paving the way for resilient and adaptable operations.

If you are curious about the future of resilient manufacturing, digital twins, and adaptive automation, this episode provides both strategic and practical insights.

Timestamps

00:00 Introduction live from Automate 2025 at Siemens booth
01:00 Guest introductions and roles at Siemens
02:00 Defining manufacturing resilience in today’s environment
04:00 Workforce challenges and empowering teams to drive adoption
05:00 Why digital twin is the starting point for resilient operations
07:00 Digital twin adoption for small and medium manufacturers
09:00 Collaborative engineering environments and the metaverse
10:00 Challenges and opportunities at the cutting edge of automation
11:00 Copilot technologies for operators and engineers
12:30 Connecting digital twins with copilots across engineering and operations
13:30 Automation lifecycle management explained
14:30 Future deep dive preview on automation lifecycle management

References mentioned in this episode

Siemens Digital Industries: https://www.siemens.com/global/en/products/automation.html
Jeff Burnstein and Automate coverage: https://www.automateshow.com/

About the hosts

Vlad Romanov is an engineer, consultant, and co host of the Manufacturing Hub Podcast. With over a decade of experience in manufacturing and industrial automation, Vlad has worked with global companies such as Procter and Gamble and Kraft Heinz, focusing on digital transformation, SCADA and MES deployments, and operational excellence. He also leads Joltek, a consulting firm helping manufacturers modernize operations. Learn more at https://www.joltek.com/

Dave Griffith is a consultant and co host of the Manufacturing Hub Podcast. He has extensive experience helping manufacturers and technology companies bridge the gap between strategy and execution, with a focus on scaling digital transformation initiatives. Dave frequently speaks on topics including systems integration, leadership, and the evolving role of technology in industrial operations.

About the guests

Chris Stevens is responsible for customer experience at Siemens Digital Industries. His focus is on people and processes, ensuring that technology deployments deliver meaningful outcomes, adoption, and long term value for customers.

Annemarie Breu leads the Accelerator Deployment Team at Siemens Digital Industries. She specializes in implementing Siemens technologies beyond the pilot stage, scaling adoption, and ensuring that digital solutions create measurable business outcomes.

If you enjoy this conversation, make sure to subscribe to Manufacturing Hub for more interviews from Automate 2025 and beyond.

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 turning a corporate initiative into an actionable plant-level strategy, from limited baseline data to deciding between standalone meters and integrated monitoring solutions. Vlad shares the lessons learned in balancing cost, data ownership, and scalability, and why a more open solution can sometimes offer greater long-term value than proprietary systems.

Dave then takes us into the world of pet food manufacturing, where millions of dollars in raw materials can be lost each year due to inaccurate batching and poor measurement practices. He walks through the process of defining the problem, setting up data collection without overhauling legacy systems, and using that information to identify overages, improve tolerances, and design remediation strategies. The conversation dives into practical engineering decisions, such as when to invest in VFDs for precision dosing, when to redesign process equipment, and how to ensure data insights lead to lasting operational changes.

The discussion expands into organizational challenges, including why decision-makers often lack actionable visibility into losses, how to present findings in terms of tangible business impact, and the cultural shift required to actually use the data once it is available. Vlad and Dave also explore examples from discrete manufacturing, where OEE tracking and daily direction setting (DDS) meetings help guide capital allocation, continuous improvement initiatives, and team alignment. They share observations on why some facilities succeed with these systems while others fall back into old habits.

Timestamps
00:00 Introduction to Episode 221 and monthly theme recap
02:00 Vlad’s background and approach to modernization projects
04:50 Dave’s background and focus on data-driven manufacturing solutions
06:30 Recap of previous episodes on data collection, historians, and MTP/MCP
07:30 Vlad’s Procter & Gamble energy monitoring project case study
13:40 Addressing power blips, capacitor banks, and ROI considerations
19:10 Choosing between proprietary and open monitoring solutions
23:40 Dave’s pet food manufacturing story and raw material variance
29:50 Methods for data collection without disrupting legacy systems
34:20 Improving accuracy, process changes, and remediation strategies
44:00 Organizational challenges in acting on data insights
52:00 OEE, DDS meetings, and capital allocation in discrete manufacturing
59:50 Predictions for the future of manufacturing intelligence and AI integration

References Mentioned
Ignition by Inductive Automation – https://inductiveautomation.com/
Ignition Community Conference (ICC) – https://icc.inductiveautomation.com/
Procter & Gamble – https://us.pg.com/
Rockwell Automation – https://www.rockwellautomation.com/
Mettler Toledo – https://www.mt.com/
Badwater Ultramarathon – https://www.badwater.com/
“Can’t Hurt Me” by David Goggins – https://davidgoggins.com/book/

About the Hosts

Vlad Romanov works with manufacturers to modernize operations by bridging the gap between legacy systems and today’s technology. He specializes in assessing current states, designing scalable architectures, and implementing solutions across control systems, SCADA, and MES infrastructures. His mission is to help plants run better from a technical and operational standpoint, whether through unlocking critical data from PLCs or leading full-scale digital transformation initiatives.
Connect with Vlad: https://www.linkedin.com/in/vladromanov/

Dave Griffith has over 16 years of experience in automation and manufacturing, with a technical foundation in aviation and aerospace. His work spans from OEM manufacturing to food and beverage production, with a strong focus on data-driven projects that deliver ROI. Dave leads teams at Kaplan to unlock operational data, design integration strategies, and deploy solutions that improve efficiencies and reduce waste.
Connect with Dave: https://www.linkedin.com/in/davegriffith/

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 shifts, and implementation considerations that make this vision a reality.

Key topics covered include:

• Why traditional SCADA and MES architectures are not AI-ready
• The real-world value of MTP in legacy Brownfield plants
• How Siemens’ Machine Proxy App and OPC UA servers act as translators between AI models and legacy PLCs
• Differences between machine states, control interfaces, and orchestrated services in modular manufacturing
• Why CLI skills and edge computing are foundational for the modern control engineer
• How to pitch digital transformation and AI investments to hesitant executives

We also touch on organizational psychology, how internal champions get ignored without executive alignment, and the grim future for manufacturers still betting on ice cube relays.

Whether you’re a plant engineer, systems integrator, or digital transformation leader, this conversation offers a bold but practical look at how to safely integrate AI into manufacturing control environments: starting with protocols and principles, not just hype.

🧠 Resources Mentioned:

• Siemens Industrial Edge: https://new.siemens.com/global/en/products/automation/industrial-edge.html
• Machine Context Protocol (MCP): https://www.anthropic.com/news/introducing-the-machine-context-protocol
• VDI MTP Standard: https://www.vdi.de/
• Book Recommendation: How the World Really Works by Vaclav Smil

👤 Guest: Caleb Eastman, Siemens
📌 Theme: Data Foundations and Intelligent Manufacturing
🎙️ Hosts: Vlad Romanov & Dave Griffith

✅ Key Timestamps

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.

We cover critical trends shaping the next generation of manufacturing, including the rise of virtual PLCs (vPLCs), integration of AI into control systems, the shift from hardware to software-defined automation, and the challenges of IT and OT convergence. Bernd also highlights the importance of version control, DevOps pipelines, and open edge development in making industrial systems more agile.

We wrap up by looking at Siemens' global R&D structure, freemium software models for engineers, and how manufacturers can take their first steps into digital transformation—without boiling the ocean.

This is a must-watch conversation for engineers, IT leaders, and decision-makers in the automation space looking to understand what the future of control and connectivity looks like.

🔗 Mentioned Tools and Technologies:

• Siemens S7-1200 and S7-1500
• Siemens TIA Portal
• Siemens Sematic X
• Siemens Industrial Edge & Edge Developer Kit
• Siemens Unified
• vPLC (Virtual PLC)
• Codesys
• Git-style source control for automation
• AI Copilots for engineering and operations

📍 Timestamps:
 00:00 Welcome and intro to Bernd Raithel’s new role
 02:00 Siemens legacy in Johnson City and product milestones
 04:00 Why software-defined automation is gaining traction
 06:00 Edge computing, vPLCs, and building flexible architectures
 08:00 The real-world challenges of IT and OT integration
 10:30 Sematic X, version control, and agile OT tools
 13:00 How Siemens runs global R&D across multiple continents
 15:00 The future of manufacturing and PLC longevity
 17:00 Balancing modern tools with 30-year lifecycle expectations
 19:00 Starting points for digital transformation with Industrial Edge
 20:00 Siemens freemium strategy and access to tools for engineers

📚 Learn More:

• Siemens Industrial Edge: https://new.siemens.com/global/en/products/automation/topic-areas/industrial-edge.html
• TIA Portal: https://new.siemens.com/global/en/products/automation/topic-areas/tia-portal.html
• Sematic X: https://new.siemens.com/global/en/products/automation/topic-areas/sematic-x.html
• Siemens Unified: https://new.siemens.com/global/en/products/automation/topic-areas/unified.html
• Siemens vPLC: https://new.siemens.com/global/en/products/automation/industry-software/virtual-plc.html
• Siemens Developer Trials: https://plcnext-community.net/

Welcome to Episode 219 of Manufacturing Hub. In this episode, we dive into the evolution of industrial data infrastructure with Jeroen Coussement, Founder and CEO of Factry. Factry is building modern historian and MES software platforms that help manufacturers collect, contextualize, and act on operational data at scale.

We unpack the critical role of historians in modern manufacturing environments. While traditional historians focused on archiving time-series data, today’s requirements go far beyond that. Jeroen outlines how a modern historian must fulfill three foundational roles:
Efficient high-volume time-series data acquisition
Contextual modeling across complex factory assets
Democratized access and self-service tools for operations teams

This episode covers:
The differences between SCADA, MES, and historians
The evolution from legacy platforms like OSIsoft PI to cloud-native historians
Architectures for on-prem, cloud, and hybrid historian deployments
Real-world use cases like wind turbine optimization for shadow flicker mitigation
Common challenges in digital transformation, including network modernization and change management
How manufacturers can scale from data collection to full analytics enablement

Jeroen also shares why point solutions often lead to fragmentation, and how building a robust data foundation opens the door to advanced tools like AI, unified namespace, and better decision-making.

📍 Guest: Jeroen Coussement, Founder and CEO at Factry
🌐 https://www.factry.io

📚 Resources Mentioned:
Factry Historian: https://www.factry.io/products/factry-historian
IT/OT Insider: https://insider.itot.io
Canary Historian: https://www.canarylabs.com/
AVEVA PI System: https://www.aveva.com/en/solutions/pi-system/
GE Proficy Historian: https://www.ge.com/digital/applications/historian
Joltek Consulting: https://www.joltek.com/

⏱️ YouTube Timestamps
00:00 Intro and welcome
02:00 Jeroen’s journey from bioscience engineer to founder of Factry
05:00 What is an industrial historian and why it matters
09:00 The relationship between SCADA, MES, and historians
12:00 Legacy historian vendors and what’s changing
15:00 The shift to cloud-native and open data systems
18:00 When and why manufacturers choose to implement a historian
21:00 Software cost vs implementation cost
23:00 Common historian architectures: on-prem, cloud, hybrid
27:00 Regional differences in adoption across US and Europe
30:00 Use case: Wind turbine shadow flicker mitigation via historian
35:00 Can historians ever feed data back into PLCs?
39:00 Change management and user training are key
42:00 Layering MES and quality tools on top of a historian
46:00 Why point solutions fail and unified platforms win
49:00 Empowering domain experts with self-service analytics
52:00 Predictions for the future of historians
54:00 Career advice for those entering the industrial data space
56:00 Who should reach out to Factry

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/

⏱️ Timestamps
00:00 Introduction and Overview of Data Collection Theme
02:00 Brian’s Journey into Controls Engineering and Integration
06:30 What Legacy Manufacturing Equipment Actually Looks Like
10:00 Why Data Collection is Often an Afterthought in Scope
13:50 The Disconnect Between Machines and Business Systems
17:00 Real-World Discovery Process for Machine Connectivity
22:00 Overcoming Internal Resistance to Data-Driven Projects
28:00 Strategies for Extracting Data from Obsolete PLCs
34:30 Direct Sensor to SCADA vs PLC-Driven Design Debate
41:00 Flattening the Architecture and Breaking the Purdue Model
55:00 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/

⏱️ Timestamps
00:00 – Intro and Overview of Robotics Coverage
03:00 – Pawel Krupa Introduction and Robotics Background
05:00 – Cybersecurity-Driven Changes to Industrial Robots
06:30 – Fanuc R-50iA Cabinet Updates and Python Integration
11:00 – KUKA KC5 and iiQ OS: New Hardware and Software Paradigm
15:00 – ISO Changes and Safety Implications for Cobots
17:00 – Industrial Applications and ROI for Humanoid Robots
30:00 – Practical AI Use Cases in Robotics and Vision Systems
40:00 – AI Vision System Setup: From Demo to Deployment
49:00 – Startup Idea: Optimizing Robot Motion via AI
57:00 – 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 practice
The real-world complexity of end-of-arm tooling and vision systems
Why standardization is critical for both integrators and manufacturers
What robotics programming and automation roles will look like in the next five years
The practical limits of robots-as-a-service and humanoid hype
Using generative AI and GPTs to assist in controls programming
Career advice for engineers breaking into robotics and automation

Plus, 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: [email protected]
🔗 Connect with Vlad: https://www.linkedin.com/in/vladromanov
🔗 Learn more about Joltek: https://www.joltek.com