Ep. 232 - Future of Automation with Siemens: Industrial AI, Virtual PLCs, and Digital Twin Factories

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 introduction02:45 Defining manufacturing resilience and digital twins09:32 Virtual commissioning and collaborative engineering environments15:10 Adoption of digital twins in small and medium manufacturers22:35 Co-pilots and natural language interaction in industrial systems30:28 Automation lifecycle management and version control for PLCs36:55 Virtual PLCs, software-defined automation, and IT/OT collaboration46:40 The new Siemens S7-1200 G2 PLC and migration from G157:20 AI copilots, agents, and secure Siemens cloud infrastructure1:08:05 Somatic AX and modern PLC programming for new engineers1:17:25 Pick AI Pro and real-world robotic vision applications1:29:10 G220 drives and clean power innovations1:35:45 Industrial cybersecurity and vulnerability management1:43:00 Cinemeric Run My Robot and CNC-robot collaboration1:50:20 Final reflections on Siemens innovation and future trendsReferences Mentioned:Siemens Digital IndustriesSiemens Industrial Edge Developer KitS7-1200 G2 InformationSematic AXIndustrial CopilotCinematic Run My RobotPick AI ProSiemens G220 DrivesCybersecurity SolutionsManufacturing HubModern Plant Network Requirements: Building Reliable and Connected OT Systems for ManufacturingAbout 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 outlookReferences 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.htmlSiemens 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-machineSiemens 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-deviceSiemens IPC BX 59 A Operating Instructions https://support.industry.siemens.com/cs/attachments/109972660/ipcbx56a_and_ipcbx59a_operating_instructions_enUS_en-US.pdfUniversal Robots Example with Simatic Robot Pick AI https://support.industry.siemens.com/cs/document/109822788/simatic-robot-pick-ai-with-universal-robots-ur5Zivid Transparent Object Imaging Information https://www.zivid.com/zivid-omni-engine-transparency https://blog.zivid.com/zivid-omni-engineSiemens 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.comYouTube Channel https://www.youtube.com/channel/UC6JpBeS_6JhUwfGF8RgLCIQDave 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.Timestamps00:00 Welcome and ICC traditions with stickers and community shoutouts01:25 What to expect today and why this episode includes a sit down with Travis02:30 First impressions of ICC 2025 tracks vendor hall and ProveIt showcases05:55 New Sacramento venue experience and why more space improved conversations07:25 Walk up tickets record attendance and what that signals about growth08:45 Why hands on ProveIt demos mattered for real integrations and learning12:05 Ignition 8.3 launch and what we will cover in more depth later this month13:25 AI themes across sessions and realistic use cases for builders and operators16:20 Why OT networking education is now a must have skill set18:05 DataOps and DevOps directions in Ignition 8.3 and what to trial first23:10 Travis Cox joins with ICC takeaways and how community scale changes the game28:35 Ignition 8.3 highlights configuration in files REST API and version control workflowsAbout the hostsVlad Romanov manufacturing modernization and data strategy consultant co host of Manufacturing Hub and founder of JoltekLinkedIn https://www.linkedin.com/in/vladromanovJoltek https://www.joltek.comDave Griffith operations and digital transformation consultant co host of Manufacturing HubLinkedIn https://www.linkedin.com/in/davegriffith23Website https://dave-griffith.comGuestTravis Cox Chief Evangelist at Inductive AutomationLinkedIn https://www.linkedin.com/in/traviscox-automationInductive Automation https://inductiveautomation.comEpisode references and resourcesIgnition 8.3 What is new https://inductiveautomation.com/ignition/whatsnewIgnition User Manual 8.3 docs and upgrade guidance https://www.docs.inductiveautomation.comDownload Ignition free trial https://inductiveautomation.com/downloadsInductive University free Ignition training https://inductiveuniversity.comICC 2025 recap https://inductiveautomation.com/blog/icc-2025-recap-we-really-did-level-up-this-yearControl Global highlights from ICC 2025 https://www.controlglobal.com/industry-news/news/55321625/highlights-from-inductive-automations-2025-icc-build-a-thon-and-award-winnersProveIt Conference official site https://www.proveitconference.comProveIt at ICC background https://inductiveautomation.com/blog/proveit-showcases-are-coming-to-icc-2025Books and learning mentioned or implied in the discussionNetworking and cybersecurity training via Inductive University https://inductiveuniversity.comIgnition 8.3 videos and feature overviews https://www.youtube.com/watch?v=Qds7RI9-hxgConnect with Manufacturing HubApple Podcasts https://podcasts.apple.com/us/podcast/manufacturing-hub/id1546805573Spotify https://open.spotify.com/show/1gE6glbxdYIfG6KUeOCz22Call to actionIf 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 adviceReferences 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 professionalsReferences 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.comAbout 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 resourcesReferences 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.htmlAbout the HostsVlad 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/vladromanovDave 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/davegriffithJoltek 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. 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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.Timestamps00:00 Introduction and welcome with Dave, Vlad, and Kevin02:00 Kevin’s background and entry into industrial software05:00 Lessons from early HMI and integrator experiences07:30 The importance of integrators in Inductive Automation’s go-to-market strategy09:00 Transition into sales leadership and learnings from global customers13:00 Ignition 8.3 beta release process and development challenges18:00 Historian improvements and introduction of QuestDB21:00 The new Siemens driver and why it matters globally27:00 Use cases for multiple historians and large-scale data performance31:00 Kafka integration, Event Streams, and IT-OT convergence35:00 DevOps capabilities in Ignition including Git and deployment modes41:00 Preview of the Ignition Community Conference and new venue44:00 The Hub, CoLab, and community-driven sessions at ICC50:00 Prove It sessions and exhibitor highlights56:00 The Build-On competition and its evolution01:01:00 Predicting the future of ICC and Ignition01:03:00 Kevin’s career advice for engineers and integrators01:05:00 How listeners can connect with Inductive AutomationReferences Mentioned in the EpisodeInductive Automation: https://inductiveautomation.com/Ignition 8.3 Beta Release Notes: https://inductiveautomation.com/downloads/release-notesQuestDB: 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 HostsVlad 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 GuestKevin 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.Timestamps00:00 Introduction live from Automate 2025 at Siemens booth01:00 Guest introductions and roles at Siemens02:00 Defining manufacturing resilience in today’s environment04:00 Workforce challenges and empowering teams to drive adoption05:00 Why digital twin is the starting point for resilient operations07:00 Digital twin adoption for small and medium manufacturers09:00 Collaborative engineering environments and the metaverse10:00 Challenges and opportunities at the cutting edge of automation11:00 Copilot technologies for operators and engineers12:30 Connecting digital twins with copilots across engineering and operations13:30 Automation lifecycle management explained14:30 Future deep dive preview on automation lifecycle managementReferences mentioned in this episodeSiemens Digital Industries: https://www.siemens.com/global/en/products/automation.htmlJeff Burnstein and Automate coverage: https://www.automateshow.com/About the hostsVlad 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 guestsChris 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.Timestamps00:00 Introduction to Episode 221 and monthly theme recap02:00 Vlad’s background and approach to modernization projects04:50 Dave’s background and focus on data-driven manufacturing solutions06:30 Recap of previous episodes on data collection, historians, and MTP/MCP07:30 Vlad’s Procter & Gamble energy monitoring project case study13:40 Addressing power blips, capacitor banks, and ROI considerations19:10 Choosing between proprietary and open monitoring solutions23:40 Dave’s pet food manufacturing story and raw material variance29:50 Methods for data collection without disrupting legacy systems34:20 Improving accuracy, process changes, and remediation strategies44:00 Organizational challenges in acting on data insights52:00 OEE, DDS meetings, and capital allocation in discrete manufacturing59:50 Predictions for the future of manufacturing intelligence and AI integrationReferences MentionedIgnition 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 HostsVlad 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-readyThe real-world value of MTP in legacy Brownfield plantsHow Siemens’ Machine Proxy App and OPC UA servers act as translators between AI models and legacy PLCsDifferences between machine states, control interfaces, and orchestrated services in modular manufacturingWhy CLI skills and edge computing are foundational for the modern control engineerHow to pitch digital transformation and AI investments to hesitant executivesWe 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.htmlMachine Context Protocol (MCP): https://www.anthropic.com/news/introducing-the-machine-context-protocolVDI 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 Timestamps00:00 Welcome Back and Wilborn Celebration 03:30 Caleb's Career Journey from Cisco Cert to Siemens 07:40 Why CLI and Networking Skills Matter in OT 10:00 What Is MCP and Why It Matters for Safe AI 13:00 MTP Overview: The USB of Modular Manufacturing 18:00 Why AI Needs Context-Aware Control Layers 21:00 Bridging Human and AI Control Setpoints 24:30 Brownfield Integration with Siemens Machine Proxy 27:00 Making the Case for AI Investment 31:00 The Future of Safe AI in Manufacturing Plants 36:00 Organizational Resistance and Broken Engineers 42:00 When to Walk Away from Legacy-Only Cultures 46:00 Practical MTP Implementation and Mapping 54:00 Who Maintains MTP and How the Standard Is Evolving 58:00 Predictions: LLMs Will Become Obsolete 01:03:00 Hardware Opportunities and Novel Sensor Startups 01:08:00 Final Thoughts and How to Connect with Caleb