Ep. 243 - From Legacy Systems to AI Readiness A Realistic Look at Manufacturing Modernization

Technology modernization in manufacturing is not a list of shiny tools. It is a sequencing problem. In this episode of Manufacturing Hub, Vlad Romanov and Dave Griffith break down why the executive vision for AI often collides with the reality of the plant floor, and what a practical path forward actually looks like when you account for data quality, legacy controls, networking, and the true cost of integration.A core theme in this conversation is imperfect information. Leaders often believe the data already exists because reports exist. But a stack of paper, a few spreadsheets, or a single counter value is not the same as contextualized, trustworthy history that can drive decisions or support advanced analytics. Vlad and Dave walk through why foundational work matters, what teams usually miss during modernization, and how quickly the bill grows when you discover your architecture is outdated, undocumented, or full of dependencies you cannot see until you open panels and start tracing signals.You will also hear a grounded debate on how to think about SCADA, MES, historians, dashboards, and what it would actually mean to “feed data into AI” in a manufacturing context. The takeaway is simple. If you want better outcomes, you need a better understanding of your current state, a clear business case, and a roadmap that prioritizes what matters operationally. Modernization is not one big upgrade. It is a series of decisions that either reduce friction or create it.About the hostsVlad Romanov is an industrial automation and manufacturing expert focused on plant assessments, controls and data architecture, IT and OT integration, and workforce upskilling. Vlad has over 10 years of experience across large manufacturers and complex multi site environments, working from PLC and HMI layers up through SCADA, MES, and ERP integration programs. He is the founder of Joltek, where the mission is to help manufacturers modernize safely, build internal capability, and deliver results that actually survive handoff to operations.Learn more about Joltekhttps://www.joltek.comhttps://www.joltek.com/servicesDave Griffith is an industrial automation practitioner and consultant who works closely with manufacturers to modernize legacy environments, improve reliability, and build practical systems that operators and maintenance teams can support. Dave brings a strong perspective on what is feasible in real plants, where uptime, risk, budget, and organizational readiness drive every decision.Timestamps00:00:00 Welcome and why this month is about technology modernization00:02:10 The real problem with “just add AI” in manufacturing00:04:15 Quick background on Vlad and Dave and the work they do00:05:25 The disconnect between the perfect factory vision and the plant floor00:06:25 Vlad on business cases, integration reality, and infrastructure gaps00:09:05 Dave on imperfect information and why reports are not data00:14:35 What executives actually want from AI and why it is often about people constraints00:20:25 How to get there, hardware first, data normalization, and context00:22:05 Vlad on assessments, legacy hardware, and why upgrades get complicated fast00:39:00 New facility planning mistakes and why early decisions lock you in00:45:10 You have the data, now what, OEE baselines, bottlenecks, and root causes00:58:10 Final takeaways, inventory your architecture and treat data like an assetReferences and links mentionedManufacturing Hub Podcasthttps://www.manufacturinghub.liveProveIt Conferencehttps://www.proveitconference.comAutomate Showhttps://www.automateshow.comIgnition Community Conferencehttps://icc.inductiveautomation.comIf you are watching on YouTube, subscribe so you do not miss the rest of this month’s deep dives on hardware, data teams, and practical applications that actually work on real plant floors.

In this episode of Manufacturing Hub, hosts Vlad Romanov and Dave Griffith welcome back Amos Purdy for a wide ranging conversation that connects plant floor reality with SCADA, MES, and the business decisions that actually fund modernization. Amos shares his path from early software and programming work into industrial automation, including building an industrial automation class and lab, leading MES and SCADA efforts, and working across industries where the pace, constraints, and validation expectations can feel like completely different worlds. If you have ever wondered why a solution that looks obvious on a whiteboard takes months or years to land on a production line, this episode breaks down the human, technical, and financial reasons in plain terms.A big thread throughout the conversation is what it takes to build systems that last. The group digs into hiring and mentoring for Ignition based teams, what backgrounds translate well, and why “hobbyist energy” can be a real superpower in interviews and on the job. The practical takeaway is simple: credentials help you get in the door, but projects help you stand out, especially when you can explain the problem, the architecture, and the tradeoffs you made. The conversation also gets real about legacy plants, where the constraint is often not ambition but risk, ROI, and operational disruption. The group frames modernization as a sequence of targeted moves that improve data availability, reduce cybersecurity exposure, and create a foundation for future applications without betting the entire facility on a massive rip and replace.You will also hear a grounded take on AI in industrial settings. The panel separates what is useful today from what is still hype, and explains why industrial AI needs context, standards, and purpose built training data to be trusted. They connect that to the “data transparency” problem: companies want answers faster, but the hard part is making the data accessible, reliable, and safe in the first place. The episode closes with a discussion on EV and battery manufacturing trends, the reality of global standards and certification, and what the next few years could look like as edge devices, connectivity, and power systems evolve.HostsVlad Romanov is an industrial automation and manufacturing systems expert focused on SCADA, MES, OT data infrastructure, and modernization strategy. He combines electrical engineering depth with an MBA from McGill University to help manufacturers reduce risk, improve reliability, and turn plant data into decision ready information. He leads Joltek, where he delivers assessments, integration roadmaps, and practical upskilling for engineering and operations teams.Dave GriffithManufacturing and automation leader focused on bridging business outcomes with engineering execution, change management, and scalable plant systems.GuestAmos PurdyMBA and electrical engineering background with deep experience across industrial automation, SCADA, MES, and manufacturing intelligence, including leading teams and deployments in both legacy and greenfield environments.Timestamps00:00 Welcome to Manufacturing Hub and why this episode sets up the upcoming modernization theme02:20 Amos Purdy returns and reintroduces his background03:00 From early programming to industrial automation, lab building, and MES leadership09:40 Switching industries and why vertical experience is often overvalued12:40 Hiring and mentoring for Ignition, web skills vs plant floor instincts16:10 AI vs fundamentals, why legacy tech knowledge still matters17:20 Growing teams and how managers should match work to strengths20:10 How candidates stand out, hobby projects and real systems thinking22:50 Technology modernization, data visibility, and cybersecurity as the forcing function31:50 The real bottlenecks, selling ROI, scoping, and avoiding project blowouts37:30 AI readiness in industry, what works today and what is not there yet41:00 EV and battery manufacturing, investment, standards, and what changes on the shop floor50:40 Predictions for the future, edge devices, connectivity, and more data everywhere54:20 Book recommendation and why macro trends matter for engineers56:00 Where to find Amos and what to reach out aboutReferences and links mentionedIgnition by Inductive Automationhttps://inductiveautomation.com/ignitionIgnition SCADA overviewhttps://inductiveautomation.com/scada-softwareInductive University traininghttps://inductiveuniversity.comProveIt Conference 2026 detailshttps://www.proveitconference.comEdison Motorshttps://www.edisonmotors.ca2030: How Today’s Biggest Trends Will Collide and Reshape the Future of Everything by Mauro F. Guillénhttps://us.macmillan.com/books/9781250772213/2030howtodaysbiggesttrendswillcollideandreshapethefutureofeverything/https://www.joltek.com/serviceshttps://www.joltek.com/education/ot-networking-fundamentals

Welcome to Manufacturing Hub and welcome to 2026. In this kickoff episode, Vlad Romanov and Dave Griffith reset the table for the year and share what the show is really about: practical conversations with people who build, run, secure, and modernize manufacturing systems. If you are new here, this is the perfect starting point because we explain the format, the monthly themes, and the reason we keep coming back to the same hard truth: manufacturing improvement is never just about technology. It is also about people, process, incentives, and change.From there, we get into the big question everyone is asking right now: what actually changes in 2026 for manufacturing and industrial automation. We talk about why AI stopped being a novelty and started becoming a permanent part of the landscape, and we separate the hype from the applications that are starting to look real. We discuss where AI helps today, where it still struggles, and why most teams will not get value until they build stronger fundamentals in data collection, context, and operational ownership. We also connect the dots between AI and the pressure it puts on infrastructure, security posture, and decision making, especially when the plant floor reality is still paper logs, tribal knowledge, and inconsistent system documentation.We also cover what we expect to see across the core pillars of the industrial stack: plant floor data and operations, engineering and commissioning workflows, back office analytics, OT cybersecurity, industrial data platforms, and how the systems integration market is evolving as more work moves upward into analytics, architecture, and long term modernization programs. Finally, we zoom out into careers, acquisitions, private equity activity, and what these shifts mean for engineers, leaders, and teams trying to build durable capability instead of chasing the next shiny tool.If you are planning your year, come meet us in person. We will be at ProveIt in Dallas, Texas February 16 to 20. We will also be at Automate in Chicago, Illinois June 22 to 26. And we are expecting to be back at the Ignition Community Conference in Sacramento, California September 22 to 26.Timestamps00:00 Welcome to 2026 and why we are back 01:00 What Manufacturing Hub covers and how the show is structured 02:35 Meet the hosts Dave Griffith and Vlad Romanov 04:55 Where to meet us in 2026 ProveIt Automate ICC 07:45 The state of manufacturing and what is changing this year 08:35 AI in manufacturing from curiosity to permanence 12:20 Plant floor data reality and why fundamentals still block progress 18:10 AI in engineering and commissioning where it helps and where it can hurt 24:30 Back office work and the real adoption patterns 31:00 OT cybersecurity pressure and why posture work is accelerating 38:10 Industrial data priorities and what to fix before you scale 44:40 Systems integration shifts careers and the ripple effects of acquisitions 1:03:00 Our plans for 2026 1:10:45 Book recommendation and closing thoughtsHostsVlad Romanov is an electrical engineer and manufacturing consultant focused on industrial automation, modernization, OT data, and IT OT alignment. He runs Joltek and builds educational content for engineers and technical leaders.Dave Griffith has 17 plus years in industrial automation and manufacturing and leads Kaplan Solutions, focused on operational excellence, data systems, and delivering projects that make plant performance visible and actionable.References mentionedHow to tackle the AI skills gap, Boston Consulting Group https://www.linkedin.com/pulse/how-tackle-ai-skills-gap-boston-consulting-group-ufzgeWhat’s Next for AI in 2026, MIT Technology Review https://www.technologyreview.com/2026/01/05/1130662/whats-next-for-ai-in-2026/Getting Naked, Patrick Lencioni https://www.tablegroup.com/product/getting-naked/

Handing over a project is one of the most underestimated and misunderstood phases in manufacturing and industrial automation. In this episode of Manufacturing Hub, Vlad and Dave sit down to break apart real stories from the field covering MES rollouts, line commissioning, SCADA and ignition development, operational adoption, and the very real consequences of poor knowledge transfer. Most conversations online focus on the technical build, but very few people emphasize the point where engineering lets go and the operations team becomes the true owner of the system. This episode brings forward examples of both well executed handovers and catastrophic failures that every engineer, integrator, or manager can learn from.Vlad begins by walking through his experience building MES and data collection systems for food and beverage facilities where each plant had different architectures, legacy systems, undocumented networks, and obsolete PLCs. These initiatives required deep assessments, phased modernization, server deployments, KPI development, and the long journey from data collection to actual operational use. The most important insight is that success rarely comes from the technology alone. It comes from the extent to which operators, supervisors, and CI teams are trained, empowered, and aligned to use what has been built.Dave then shares a story from a multi year track and trace project that technically worked but failed at the operational handover stage because the one scheduler refused to schedule inside the system. The entire project was mothballed despite millions of dollars invested. The lesson is simple. Technology cannot compensate for missing stakeholder alignment and poor discovery. Human influence can halt even the most well engineered solution.Timestamps 00:00 Welcome and episode setup 01:20 Host introductions and backgrounds 04:00 Vlad’s MES and data rollout projects across multiple plants 18:10 Biggest wins and failures from MES handovers 26:20 Dave’s chocolate factory MES and traceability project 29:30 The scheduler says no and a multi million project gets mothballed 36:40 Lessons learned about scope creep and realistic timelines 42:00 Vlad’s multimillion packaging line rollouts and OEE based handover 49:20 Internal versus external teams and who really owns change 58:50 Connected workforce at an orange juice plant and knowledge capture 01:15:00 Where project handovers are heading in the next three to five years 01:19:00 Career advice, books, and final thoughts HostsVladimir RomanovFounder of Joltek. Electrical engineer with an MBA from McGill University. More than a decade of experience across Procter and Gamble, Kraft Heinz, Post Holdings, and multiple systems integration roles. Specializes in OT systems, industrial data architecture, MES, SCADA, modernization, and digital transformation. Works with manufacturers to unlock value through data and operational decision support.https://www.joltek.com/team-members/vladimir-romanovDave GriffithFounder of Kaplan Solutions. Seventeen plus years of experience across aerospace, automation, system integration, MES delivery, and enterprise manufacturing systems. Dave specializes in ignition development, operations consulting, and project delivery frameworks that reduce risk and increase adoption across manufacturing teams.References Mentioned in the EpisodeNever Split The Difference by Chris Vosshttps://www.amazon.com/Never-Split-Difference-Negotiating-Depended/dp/0062407805How To Win Friends and Influence People by Dale Carnegiehttps://www.amazon.com/How-Win-Friends-Influence-People/dp/0671027034Traction by Gino Wickmanhttps://www.amazon.com/Traction-Get-Grip-Your-Business/dp/1936661837The E Myth Revisited by Michael Gerberhttps://www.amazon.com/Myth-Revisited-Small-Businesses-About/dp/0887307280Understanding Plant NetworksManufacturing Execution SystemsManufacturing Digital Maturity and AssessmentsControl System ModernizationEngineering Project Management EssentialsManufacturing Consulting and Change Management

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.Timestamps00:00 Introduction to systems integration month01:10 Vlad background and career in manufacturing and automation03:00 Dave background and experience running an integration company04:40 What a systems integrator actually is in modern manufacturing07:50 The blurry line between integrators machine builders and software providers08:50 Why people decide to start a systems integration company12:40 Contractor mindset versus building a real business16:50 Early startup requirements insurance registration tools licenses22:00 Sales marketing and the challenge of finding early customers27:00 How timing relationships and visibility drive new work30:00 Referrals partnerships and brand building for technical founders33:20 Understanding financials hourly rates project rates and risk40:00 Negotiating payment terms net cycles and cashflow management43:30 Technology choices internal tools external platforms and vendor ecosystems51:10 Should you specialize or learn every platform54:20 When to say no and how to evaluate incoming work58:00 Hiring your first employee and the reality of scaling01:03:20 The future of systems integration over the next three to five years01:08:00 Final career advice for engineers considering integration01:12:00 Resources and closing thoughtsSystems integrators articlehttps://www.joltek.com/blog/system-integratorsManufacturing consulting insightshttps://www.joltek.com/blog/manufacturing-consultingDigital transformation in manufacturinghttps://www.joltek.com/blog/digital-transformation-in-manufacturingIndustrial cybersecurity fundamentalshttps://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.Timestamps00:00 Introduction to the Ignition Community Conference and the Student Buildathon01:25 How the Educational Engagement Program at Inductive Automation was created03:22 The origin story behind the Student Buildathon concept05:16 How the seventy two hour challenge works for student competitors06:44 Requirements for student teams and how the selection process works08:49 Why universities struggle to adopt new technology and how industry partnerships help10:41 How integrator involvement accelerated program adoption across universities12:28 The gap between academic theory and real industry practice14:01 Building a complete lab curriculum for professors using Ignition17:24 Why students should learn both modern and legacy industrial systems18:20 Feedback from professors teaching Ignition for the first time20:59 Understanding the different educator profiles and adoption journeys23:15 How Inductive Automation built the five lab training series for schools25:17 The future of the educational program including internships and co op models27:39 Why academic co op programs are powerful for building real engineering experience29:26 How to join the Student Buildathon or the Educational Engagement ProgramVlad RomanovVlad 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 GriffithDave 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 GrussenmeyerDavid 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.comEducational inquiries can be sent to [email protected] Resources from the EpisodeInductive Automation Educational Engagement Programhttps://inductiveautomation.com/community/educationInductive Universityhttps://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.Timestamps00:00 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 applicationsBooks Mentioned Extreme Ownership – Jocko Willink and Leif Babin Buy Back Your Time – Dan Martell The BibleGuest 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 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.