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 sustainable integration practice in the world of manufacturing and industrial automation.

The episode begins by grounding the definition of a systems integrator in the context of modern industrial environments. Vlad and Dave explore the many different shapes and levels of integrators across the ISA eighty five and ISA ninety five landscape, from controls and PLC programming to SCADA development, MES implementations, and specialized software delivery. They also explain why customers hire integrators, why the most valuable asset is always the people, and why the hardest part of the work is rarely technical. Vlad shares insights from his decade in engineering and operations roles at Procter and Gamble, Kraft Heinz, and Post Holdings, followed by senior engineering and management positions at multiple systems integration firms. Dave brings his experience from aerospace, OEM machine building, distribution, and running his own integration business focused on manufacturing execution systems and ignition development.

The conversation then shifts to the earliest stages of starting an integration company. Vlad and Dave describe the moment when most professionals decide to go out on their own, which usually begins with feeling constrained by corporate structures or wanting more autonomy over the projects they work on. They break down the difference between being a contractor and building a long term business and why many technical founders underestimate the reality of sales, marketing, legal administration, cashflow management, and relationship building. The discussion highlights how timing and relationships drive early opportunities far more than technical ability and why every contract carries its own risk profile that needs to be negotiated with care.

Listeners are then guided through the real startup requirements for a systems integration company. This includes liability insurance, business registration, accounting and bookkeeping tools, mileage and expense tracking, choosing an internal technology stack, managing licenses, and understanding when to invest in programming software or rely on customer owned licenses. Vlad and Dave explain the role of net thirty, net ninety, and even net one hundred eighty payment terms and why long payment cycles can destroy cashflow if not anticipated correctly. They also share practical frameworks for setting hourly rates, pricing time and materials versus fixed projects, and calculating the true cost of travel, administration, and sales time that erode billable hours.

Timestamps
00:00 Introduction to systems integration month
01:10 Vlad background and career in manufacturing and automation
03:00 Dave background and experience running an integration company
04:40 What a systems integrator actually is in modern manufacturing
07:50 The blurry line between integrators machine builders and software providers
08:50 Why people decide to start a systems integration company
12:40 Contractor mindset versus building a real business
16:50 Early startup requirements insurance registration tools licenses
22:00 Sales marketing and the challenge of finding early customers
27:00 How timing relationships and visibility drive new work
30:00 Referrals partnerships and brand building for technical founders
33:20 Understanding financials hourly rates project rates and risk
40:00 Negotiating payment terms net cycles and cashflow management
43:30 Technology choices internal tools external platforms and vendor ecosystems
51:10 Should you specialize or learn every platform
54:20 When to say no and how to evaluate incoming work
58:00 Hiring your first employee and the reality of scaling
01:03:20 The future of systems integration over the next three to five years
01:08:00 Final career advice for engineers considering integration
01:12:00 Resources and closing thoughts

Systems integrators article
https://www.joltek.com/blog/system-integrators

Manufacturing consulting insights
https://www.joltek.com/blog/manufacturing-consulting

Digital transformation in manufacturing
https://www.joltek.com/blog/digital-transformation-in-manufacturing

Industrial cybersecurity fundamentals
https://www.joltek.com/blog/industrial-cybersecurity-ics

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 means for the future of the controls and automation workforce.

The discussion goes far beyond the event itself. David explains how the industry’s needs for engineering talent have shifted, why many academic institutions struggle to keep pace with modern automation technologies, and how Inductive Automation is supporting both professors and students to meaningfully upgrade the curriculum. The episode also explores the importance of industry partnerships, the challenge of faculty bandwidth, the value of internships and academic co op programs, and the realities of teaching automation in an evolving landscape of legacy systems, modern platforms, and everything in between.

Listeners will gain insight into how universities can adopt Ignition, how integrators can help shape the workforce pipeline, how students can develop real industry skills before graduating, and how modern industrial technology can be taught effectively without overwhelming educators. Vlad and Dave also share their own perspectives from years of integration work and reflect on how different their own educational experiences would have been if programs like this had existed earlier. This episode is educational, practical, and inspiring for anyone working in automation, industrial education, system integration, or workforce development.

Timestamps
00:00 Introduction to the Ignition Community Conference and the Student Buildathon
01:25 How the Educational Engagement Program at Inductive Automation was created
03:22 The origin story behind the Student Buildathon concept
05:16 How the seventy two hour challenge works for student competitors
06:44 Requirements for student teams and how the selection process works
08:49 Why universities struggle to adopt new technology and how industry partnerships help
10:41 How integrator involvement accelerated program adoption across universities
12:28 The gap between academic theory and real industry practice
14:01 Building a complete lab curriculum for professors using Ignition
17:24 Why students should learn both modern and legacy industrial systems
18:20 Feedback from professors teaching Ignition for the first time
20:59 Understanding the different educator profiles and adoption journeys
23:15 How Inductive Automation built the five lab training series for schools
25:17 The future of the educational program including internships and co op models
27:39 Why academic co op programs are powerful for building real engineering experience
29:26 How to join the Student Buildathon or the Educational Engagement Program

Vlad Romanov
Vlad is the founder of Joltek, co host of the Manufacturing Hub podcast, and a long time controls and manufacturing systems engineer with deep experience in SCADA, MES, data architecture, and plant digital transformation. Vlad creates practical industrial education content across YouTube, LinkedIn, and SolisPLC, and works directly with manufacturers on modernization, integration, and performance improvement initiatives. Learn more at https://www.joltek.com/

Dave Griffith
Dave is a systems integration expert, strategist, and consultant with many years of hands on work in automation, SCADA, robotics, and digital manufacturing. Dave is the co host of Manufacturing Hub and advises companies on the intersection of technical systems, operational strategy, and workforce development.

David Grussenmeyer
David Grussenmeyer is the Educational Engagement Program Manager at Inductive Automation. He leads global initiatives to support universities, colleges, faculty members, and students in adopting Ignition for hands on learning. His work has expanded the program from zero to more than three hundred academic institutions worldwide. David also created the Student Buildathon, a seventy two hour Ignition competition designed to push students to think creatively, develop real industrial projects, and gain practical skills that prepare them for careers in controls, industrial software, and automation.
Learn more about the program at https://inductiveautomation.com

Educational inquiries can be sent to [email protected]

Referenced Resources from the Episode

Inductive Automation Educational Engagement Program
https://inductiveautomation.com/community/education

Inductive University
https://inductiveuniversity.com

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 complex manufacturing solutions involving welding cells, painting robots, and palletizing systems used across multiple industries including food and beverage, fabrication, and renewables.

The discussion explores how system integrators can strategically position themselves in the modern automation ecosystem. Davide explains the importance of vendor relationships, revealing how open collaboration with companies like Fanuc and KUKA helped his firm grow while avoiding common pitfalls faced by new integrators. He provides practical insights into how to evaluate robot brands, manage the mechanical design and safety aspects of projects, and find the right balance between in-house engineering and subcontracting work.

Listeners will also hear a detailed perspective on the Texas manufacturing landscape, where oil and gas still dominate but are now accompanied by a new wave of innovation from defense, aerospace, semiconductor, and AI-driven industries. Davide explains how these shifts are creating a demand for flexible automation and robotics expertise across the region.

A large portion of the conversation focuses on the real-world challenges that come with integrating robots on the factory floor. Davide talks about dealing with customers who insist on collaborative robots when industrial robots are better suited for the job. He describes how simulation and digital twin tools can help demonstrate cycle times and prove system capabilities before implementation. His transparency about pricing, quoting, and project management makes this a must-listen episode for anyone looking to understand the business side of integration, not just the technical aspects.

The episode also explores how smaller robotics firms can collaborate with European and Asian OEMs that are entering the North American market. Davide shares the lessons he learned when working with foreign manufacturers, emphasizing that support, spare parts, and local presence are often more valuable than price alone. His advice is invaluable for early-stage integrators trying to evaluate new partnerships or decide which technologies to adopt.

As the conversation continues, Davide, Vlad, and Dave discuss what the future holds for robotics integration. Davide predicts an explosion of applications over the next few years, driven by manufacturing reshoring, labor shortages, and advancements in AI and simulation. He believes that companies who fail to automate will simply be left behind. His message to manufacturers is clear: whether you like it or not, automation will be necessary to stay competitive.

Listeners will also appreciate Davide’s insights into workforce development and training. He believes that plant operators and technicians must reskill to remain relevant in a world where machines are becoming smarter and more autonomous. He shares inspiring stories of training shop floor workers to operate robots with confidence and how empowering end users ultimately makes integration projects more successful and sustainable.

Toward the end of the episode, the group reflects on what it means to build a modern systems integration business. Davide shares lessons on quoting, scaling a team, developing repeatable processes, and thinking strategically about products versus projects. His perspective highlights the difference between being a contractor and building a true business that can scale and create long-term value.

Finally, the conversation closes with book recommendations that have shaped Davide’s thinking, including Extreme Ownership by Jocko Willink, Buy Back Your Time by Dan Martell, and of course, the timeless lessons found in The Bible. These selections capture the mindset of a leader who believes in responsibility, efficiency, and personal growth.

If you are an engineer, systems integrator, plant manager, or decision-maker in manufacturing, this episode will give you a firsthand look into the future of robotics integration. It will help you understand how to evaluate partners, manage projects, and prepare your organization for the next generation of automation.

Timestamps

00:00 Introduction and overview of the Systems Integrator theme
 03:00 Davide’s journey from Italy to Texas and his shift from oil and gas to robotics
 06:00 How Automation Stars of Texas was created and what the event represents
 07:30 The Texas manufacturing ecosystem and opportunities in automation
 10:00 Transitioning from traditional controls work to robotics integration
 12:00 The learning curve of programming robots and managing motion systems
 16:00 Deciding when to specialize versus subcontracting mechanical and electrical work
 19:00 Lessons from growing Bright IA and balancing costs, scope, and risk
 21:00 Building strong relationships with robot manufacturers such as Fanuc and KUKA
 26:00 The importance of vendor support and collaboration for small integrators
 29:00 Managing CAD and mechanical design in robotics projects
 33:00 The reality of collaborative robots compared to industrial robots
 36:00 Evaluating low-cost robotic arms and the trade-offs of price versus support
 41:00 How simulation and digital twins improve quoting and validation
 48:00 Why some robotics projects fail and how to recover or redesign them
 52:00 Working with European and Asian OEMs and lessons in market adaptation
 58:00 Advice for new integrators on partnerships, quoting, and strategy
 01:04:00 Predicting the future of robotics and automation in the next three years
 01:07:00 Career advice for engineers looking to transition into robotics
 01:11:00 Book recommendations and leadership lessons
 01:13:00 Davide’s vision for new robotic product development and AI applications

Books Mentioned
Extreme Ownership – Jocko Willink and Leif Babin
Buy Back Your Time – Dan Martell
The Bible

Guest
Davide (David) Pascucci
Founder and President, Bright IA
Website: https://brightiatx.com/
LinkedIn: https://www.linkedin.com/in/davidepascucci/

Bright IA is an automation and robotics integration firm based in Texas, providing complete engineering solutions for manufacturing environments, including welding systems, palletizing, safety integration, and industrial control design.

Hosts
Vladimir Romanov – Founder of Joltek (https://www.joltek.com), Electrical Engineer, Consultant, and Co-Host of Manufacturing Hub
Dave Griffith – Founder of Dave Griffith C...

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 automation and IT/OT convergence, Louis Narvaez on the next-generation S7-1200 G2 PLC, Kristen Sanderson on Industrial Copilot and AI agents, Sarah McGee on Sematic AX and modern PLC programming, Kevin Wu on Pick AI Pro, Ivan Hernandez on the G220 drives, and cybersecurity specialists Tilo and Gaurav on securing industrial networks.

Throughout the episode, Vlad and Dave discuss how Siemens is transforming plant operations through tools that connect the physical and digital worlds. Topics include co-pilots for engineering and operations, lifecycle management, virtual commissioning, edge computing, harmonics and clean power, and the convergence of IT and OT teams.

This conversation is a must-watch for engineers, integrators, plant managers, and decision-makers looking to understand how software-defined automation, AI, and digital twin technologies are merging to create resilient, data-driven factories.

Timestamps:
00:00 Siemens at Automate 2025 introduction
02:45 Defining manufacturing resilience and digital twins
09:32 Virtual commissioning and collaborative engineering environments
15:10 Adoption of digital twins in small and medium manufacturers
22:35 Co-pilots and natural language interaction in industrial systems
30:28 Automation lifecycle management and version control for PLCs
36:55 Virtual PLCs, software-defined automation, and IT/OT collaboration
46:40 The new Siemens S7-1200 G2 PLC and migration from G1
57:20 AI copilots, agents, and secure Siemens cloud infrastructure
1:08:05 Somatic AX and modern PLC programming for new engineers
1:17:25 Pick AI Pro and real-world robotic vision applications
1:29:10 G220 drives and clean power innovations
1:35:45 Industrial cybersecurity and vulnerability management
1:43:00 Cinemeric Run My Robot and CNC-robot collaboration
1:50:20 Final reflections on Siemens innovation and future trends

References Mentioned:

• Siemens Digital Industries
• Siemens Industrial Edge Developer Kit
• S7-1200 G2 Information
• Sematic AX
• Industrial Copilot
• Cinematic Run My Robot
• Pick AI Pro
• Siemens G220 Drives
• Cybersecurity Solutions
• Manufacturing Hub
• Modern Plant Network Requirements: Building Reliable and Connected OT Systems for Manufacturing

About the Hosts:
Vlad Romanov is an electrical engineer and manufacturing systems consultant with over a decade of experience modernizing plants and integrating SCADA, MES, and automation systems. He is the founder of Joltek and co-founder of SolisPLC, creating content that educates professionals in industrial automation.

Dave Griffith is a manufacturing consultant and co-host of the Manufacturing Hub podcast, helping manufacturers navigate digital transformation, technology adoption, and operational excellence.

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 no longer a limitation in many applications.

This episode also dives into digital thread and digital twin workflows using Siemens Process Simulate. These tools allow teams to test new products and layouts virtually before any hardware changes are made, helping reduce commissioning risk and shorten the path to production. The discussion highlights an on-booth demonstration that combines a robot with a secondary camera and a vision language model to identify products and read packaging details such as expiration dates. It is a clear example of how multimodal AI can complement traditional industrial vision systems.

A major theme throughout this conversation is resilience. In real operations, products are rarely placed perfectly. Pallets shift, orientations vary, and lighting changes throughout the day. Traditional rules-based vision systems often struggle when small variances accumulate. Kevin explains how model-free 3D picking localizes unknown objects in clutter, selects stable suction patterns based on measured dimensions, and keeps production moving without forcing operators to maintain perfect alignment.

For manufacturers in consumer packaged goods and medical devices, this is a meaningful advancement. It enables greater product variety and frequent SKU changes while maintaining engineering control. The difference is that the picking logic adapts to what the system sees rather than expecting the environment to remain static.

We also talk about practical evaluation and proof of concept. Siemens runs application testing at its Berkeley, California lab where customers can send sample parts for quick feasibility checks. A short video of their parts being picked can provide the confidence needed to move forward with a pilot project while minimizing cost and risk. For quality inspection and defect detection, Siemens also offers an Inspector station capable of learning from as few as twenty samples to identify defects in real time.

The discussion closes by looking at the future of digital manufacturing. Digital thread tools make it possible to simulate robots from multiple brands, test new configurations, and evaluate throughput virtually. Combined with edge AI and NVIDIA vision language technology, this creates faster experimentation cycles, improved reliability, and measurable gains in uptime and throughput.

Kevin’s key message is clear. Manufacturers do not need to replace existing automation to explore the benefits of AI. Start with one process, validate performance, and build from there.

Timestamps
00:00 Welcome and why real-world picking matters
00:40 Introduction to Pick AI Pro and new throughput capabilities
01:30 Multi suction patterns for stable handling of large items
02:20 Camera agnostic approach and transparent object handling
03:30 Selecting components for high-temperature environments
04:15 Use cases in consumer packaged goods and medical applications
06:45 Digital twin and digital thread with Siemens Process Simulate
08:30 Feasibility testing and customer demos at the Siemens lab
10:30 Vision language model for product identification and labeling
12:10 Evaluating with real parts and rapid testing cycles
14:20 Siemens Inspector for defect detection and visual inspection
15:40 Key takeaways and future outlook

References and Resources Mentioned
Siemens Simatic Robot Pick AI Overview
https://www.siemens.com/global/en/products/automation/topic-areas/tia/future-topics/simatic-robotics-ai.html

Siemens Press Release on Simatic Robot Pick AI Pro
 https://press.siemens.com/global/en/pressrelease/siemens-presents-future-intralogistics-simatic-robot-pick-ai-pro-enables-machine

Siemens Simatic IPC BX 59 A Industrial Edge Device with NVIDIA GPU
 https://www.automationworld.com/products/data/product/55287446/siemens-ag-siemens-simatic-ipc-bx-59a-industrial-edge-device

Siemens IPC BX 59 A Operating Instructions
 https://support.industry.siemens.com/cs/attachments/109972660/ipcbx56a_and_ipcbx59a_operating_instructions_enUS_en-US.pdf

Universal Robots Example with Simatic Robot Pick AI
 https://support.industry.siemens.com/cs/document/109822788/simatic-robot-pick-ai-with-universal-robots-ur5

Zivid Transparent Object Imaging Information
 https://www.zivid.com/zivid-omni-engine-transparency

https://blog.zivid.com/zivid-omni-engine

Siemens Digital Thread Overview and Tecnomatix Process Simulate
 https://www.sw.siemens.com/en-US/digital-thread/

https://plm.sw.siemens.com/en-US/tecnomatix/

NVIDIA Vision Language Model Resources
 https://docs.nvidia.com/nim/vision-language-models/latest/introduction.html

https://developer.nvidia.com/blog/vision-language-model-prompt-engineering-guide-for-image-and-video-understanding/

Hosts
Vlad Romanov is an electrical engineer and manufacturing consultant who leads Joltek and co-hosts the Manufacturing Hub Podcast. He focuses on practical strategies for SCADA, MES, and data-driven operations.
Learn more at https://www.joltek.com
YouTube Channel https://www.youtube.com/channel/UC6JpBeS_6JhUwfGF8RgLCIQ

Dave Griffith is a manufacturing consultant and long-time co-host of Manufacturing Hub. He helps teams align operations, engineering, and leadership around the projects that move the needle in real production environments.

Guest
Kevin Wu from Siemens discusses Robot Pick AI Pro and related digital thread workflows across robotics and vision. Learn more about Siemens automation and software at
https://www.siemens.com

https://www.sw.siemens.com

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 the launch of Ignition 8.3 and what it unlocks for builders who care about reliability, scale, and speed.

We discuss how 8.3’s configuration in the file system and the expanded REST API enable real version control and DevOps workflows in day to day projects. We explore practical AI opportunities through MCP servers that can safely expose context and operational data to large language models, with an emphasis on operator augmentation, faster troubleshooting, and responsible guardrails. We connect the dots between OT networking fundamentals and secure architectures by highlighting the growing need for segmentation, deterministic traffic, and resilient data movement. Throughout the episode we keep the focus on what matters in plants today clear outcomes for uptime, quality, and delivery rather than hype.

Whether you are an engineer, integrator, or an operations leader, this episode gives you an actionable snapshot of where Ignition and the broader ecosystem are heading. You will hear what the community is building, which 8.3 features are worth testing first, how ProveIt style showcases help end users evaluate technologies, and why investing in networking skills remains one of the highest ROI moves for manufacturers.

Timestamps
00:00 Welcome and ICC traditions with stickers and community shoutouts
01:25 What to expect today and why this episode includes a sit down with Travis
02:30 First impressions of ICC 2025 tracks vendor hall and ProveIt showcases
05:55 New Sacramento venue experience and why more space improved conversations
07:25 Walk up tickets record attendance and what that signals about growth
08:45 Why hands on ProveIt demos mattered for real integrations and learning
12:05 Ignition 8.3 launch and what we will cover in more depth later this month
13:25 AI themes across sessions and realistic use cases for builders and operators
16:20 Why OT networking education is now a must have skill set
18:05 DataOps and DevOps directions in Ignition 8.3 and what to trial first
23:10 Travis Cox joins with ICC takeaways and how community scale changes the game
28:35 Ignition 8.3 highlights configuration in files REST API and version control workflows

About the hosts
Vlad Romanov manufacturing modernization and data strategy consultant co host of Manufacturing Hub and founder of Joltek
LinkedIn https://www.linkedin.com/in/vladromanov
Joltek https://www.joltek.com
Dave Griffith operations and digital transformation consultant co host of Manufacturing Hub
LinkedIn https://www.linkedin.com/in/davegriffith23
Website https://dave-griffith.com

Guest
Travis Cox Chief Evangelist at Inductive Automation
LinkedIn https://www.linkedin.com/in/traviscox-automation
Inductive Automation https://inductiveautomation.com

Episode references and resources
Ignition 8.3 What is new https://inductiveautomation.com/ignition/whatsnew
Ignition User Manual 8.3 docs and upgrade guidance https://www.docs.inductiveautomation.com
Download Ignition free trial https://inductiveautomation.com/downloads
Inductive University free Ignition training https://inductiveuniversity.com
ICC 2025 recap https://inductiveautomation.com/blog/icc-2025-recap-we-really-did-level-up-this-year

Control Global highlights from ICC 2025 https://www.controlglobal.com/industry-news/news/55321625/highlights-from-inductive-automations-2025-icc-build-a-thon-and-award-winners

ProveIt Conference official site https://www.proveitconference.com

ProveIt at ICC background https://inductiveautomation.com/blog/proveit-showcases-are-coming-to-icc-2025

Books and learning mentioned or implied in the discussion
Networking and cybersecurity training via Inductive University https://inductiveuniversity.com

Ignition 8.3 videos and feature overviews https://www.youtube.com/watch?v=Qds7RI9-hxg

Connect with Manufacturing Hub
Apple Podcasts https://podcasts.apple.com/us/podcast/manufacturing-hub/id1546805573

Spotify https://open.spotify.com/show/1gE6glbxdYIfG6KUeOCz22

Call to action
If you attended ICC this year or tested Ignition 8.3 in your environment, share your lessons in the comments. Tell us which features you want us to deep dive next and what ProveIt demonstrations helped you make decisions in your own stack. Subscribe for weekly conversations with practitioners who build real systems in real factories.

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 Automation technology to launching Sepasoft’s Ignition MES modules and now leading the development of Sepa IQ, Tom has been at the forefront of data, analytics, and system integration. His insights bridge the gap between hype and practice, helping us understand where AI creates real ROI, where it still falls short, and how to build the foundations for success.

Throughout the conversation we dive into the challenges of quality improvement, predictive maintenance, scheduling optimization, and contextualizing plant data. We discuss the importance of trust in both data and AI-generated outputs, the economics of running LLMs and machine learning models, and why cybersecurity and data governance cannot be an afterthought. Drawing on the recent MIT study that revealed only 5 percent of AI projects make a measurable P&L impact, Tom helps us unpack what manufacturers need to do differently if they want to avoid being part of the 95 percent that fail.

We also get an update on Sepa IQ and how customers are using it to connect plant floor data, structure it for AI and analytics, and prepare for advanced scheduling and predictive tools. From lessons learned working with early adopters to practical advice on starting small, Tom makes it clear that manufacturing AI is a journey that requires technical expertise, domain knowledge, and cultural change.

Whether you are an executive evaluating AI investments, a controls engineer curious about new tools, or a plant manager wondering how to get real results, this episode delivers a balanced, practical, and in-depth perspective on the future of AI in manufacturing.

Timestamps
00:00 Introduction and AI in every manufacturing conversation
03:00 Tom Hechtman background and the origins of Sepasoft
05:00 MES modules, batch processing, and the evolution of Sepa IQ
08:00 Defining manufacturing AI and the role of plant floor data
13:00 Quality improvement and predictive analytics opportunities
20:00 Foundational challenges with legacy systems and data collection
24:00 Insights from the MIT study on AI adoption and ROI
32:00 Training data, context windows, and the economics of LLMs
44:00 Sepa IQ customer feedback and scheduling optimization
50:00 Trust, hallucinations, and cybersecurity considerations
59:00 ICC announcements, demos, and proof of concept program
1:03:00 Predictions for AI in manufacturing and career advice

References mentioned in the episode
MIT study on AI in business: https://mitsloan.mit.edu/ideas-made-to-matter/how-to-get-ai-to-pay-off
Sepasoft Blog on AI and manufacturing: https://sepasoft.com/blog/
The One Thing by Gary Keller: https://www.the1thing.com/

About the guest
Tom Hechtman is the founder of Sepasoft, a leading provider of MES modules for the Ignition platform by Inductive Automation. With decades of experience in manufacturing, integration, and software development, Tom has helped companies worldwide improve efficiency, quality, and data visibility. Learn more at https://sepasoft.com/
and connect with Tom on LinkedIn: https://www.linkedin.com/in/tom-hechtman-32b6b66/

About the hosts
Vlad Romanov is the founder of Joltek, a consulting and integration firm focused on helping manufacturers modernize systems, bridge IT and OT, and drive digital transformation. Learn more at https://www.joltek.com/
and connect on LinkedIn: https://www.linkedin.com/in/vladromanov/

Dave Griffith is an industrial automation consultant and co-host of Manufacturing Hub. He works with manufacturers and integrators to identify opportunities, manage digital projects, and build future-ready operations. Connect with Dave on LinkedIn: https://www.linkedin.com/in/davegriffith/

If you enjoyed this conversation, make sure to subscribe to Manufacturing Hub for more weekly discussions with industry leaders about automation, digital transformation, and the evolving world of manufacturing.

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 a specialist in OT cybersecurity. The conversation spans a wide range of issues, from asset inventory and managed switches to people, process, and technology frameworks that help organizations take the first step toward maturity.

We discuss why IT and OT teams often clash and what it takes to bridge the gap. Gavin explains the realities of budgets, the challenges of compliance, and why self-reporting frameworks often fail to reflect true maturity. He also highlights the role of legislation in Europe, rising insurance premiums, and how cybersecurity assessments can influence financial and strategic decisions at the executive level.

The episode provides clear insights into best practices such as building a proper asset inventory, structuring security awareness training for OT teams, and applying a risk-based approach to patch management. Gavin also outlines the importance of functional safety, process hazard analysis, and the role of frameworks like ISA/IEC 62443. For engineers, leaders, and decision makers, this conversation makes it clear that cybersecurity is not just a technology problem but a people and process challenge that requires long term discipline and investment.

If you want to understand what real world OT cybersecurity looks like, what mistakes to avoid, and how to set a path toward resilience, this episode is packed with valuable takeaways.

Timestamps
00:00 Introduction and upcoming ICC event
02:20 Gavin’s career journey from operator to cybersecurity expert
06:00 What ICS and OT cybersecurity really mean
09:00 Managed switches, firewalls, and securing industrial devices
11:00 The importance of people, process, and technology in security programs
13:30 Asset inventories and the first practical steps in cybersecurity
17:00 Insurance, legislation, and financial implications of OT risk
23:00 The problem with self reporting and maturity frameworks
27:00 Risk based patching strategies and CVE management
31:00 Physical keys, tokens, and access control challenges
37:00 IT versus OT ownership of cybersecurity
45:00 Certifications, training, and resources for professionals
53:00 Unified Namespace and cybersecurity considerations
58:00 Predictions for the next five years in OT cybersecurity
01:02:00 Career advice for engineers and cybersecurity professionals

References mentioned in this episode
Industrial Network Security, Eric D. Knapp (Third Edition): https://www.isa.org/products/industrial-network-security-third-edition
Security PHA Review: https://www.isa.org/products/security-pha-review-for-consequence-based-cyberse
Managing Cybersecurity in the Process Industries, ISA: https://www.isa.org/products/managing-cybersecurity-in-the-process-indust
Industrial Cybersecurity: Efficiently secure critical infrastructure systems, Steve Mustard: https://www.isa.org/products/industrial-cybersecurity-efficiently-secure-criti
Assessment Plus: https://assessmentplus.co.nz
Ignition 8.3 by Inductive Automation: https://inductiveautomation.com

About the hosts
Vladimir Romanov is an electrical engineer and MBA with over a decade of experience in manufacturing and industrial automation. He has worked with Procter and Gamble, Kraft Heinz, Post Holdings, and now leads Joltek, a consulting and integration firm focused on digital transformation and modern manufacturing systems.

Dave Griffith is an experienced systems integrator, consultant, and advisor in the industrial automation space. He has worked with manufacturers across multiple sectors, helping organizations align technology with business strategy.

About the guest
Gavin Dilworth is the founder of Assessment Plus, based in New Zealand. With a background spanning automation, controls, and cybersecurity, he helps organizations design architectures, implement policies, and build resilience in OT environments. He also mentors professionals looking to enter or advance in the ICS cybersecurity field. Connect with him here: https://www.linkedin.com/in/gavin-dilworth/

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.

Listen and Subscribe
Catch every episode of Manufacturing Hub on YouTube and your favorite podcast platforms. Subscribe to stay up to date with weekly conversations on automation, digital transformation, and the future of manufacturing.

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.