Manufacturing Hub

Automate 2026 lands in Chicago next week, and Dave and Vlad break down how to work the show floor, where to network, and what to expect from their live booth demos.Automate is the largest automation trade show in North America, and a four day event rewards preparation. Dave and Vlad share tactics refined over five years of attending together. The floor opens at 10:00 AM on Monday, and registration lines have swung from a five minute wait to nearly two hours, so arriving early matters. Monday morning and Thursday are the quietest days to reach specific vendors, while Tuesday and Wednesday draw the heaviest crowds. The hosts also favor the official show app over a paper map for finding booths and session rooms across multiple halls.The real value of a show like Automate often lives in the networking. Dave points to the A3 networking event on Monday, a ticket of roughly 45 dollars, and the Manufacturing Champions happy hour on Tuesday organized by Chris Luckey and Jake Hall. Vlad's advice is structural: build a checklist before you arrive. He researches each company, finds the booth number, and tracks every connection in a spreadsheet so the week becomes a series of deliberate meetings instead of aimless wandering. For anyone with ten or more booths on their list, setting up meetings in advance is the highest leverage move you can make.The centerpiece of the conversation is the live demo Vlad built for the Teguar booth. It pairs a Rockwell CompactLogix PLC with an Ignition gateway running on a Teguar industrial PC, and it simulates a food and beverage packaging line with five assets: filler, capper, labeler, case packer, and palletizer. The line overview screen shows real machine states including faulted, starved, backed up, and running, and the whole point is to make the bottleneck visible. When the case packer needs six bottles from the labeler but the labeler cannot keep pace, you watch the downstream asset flip between starved and running in real time. It is a practical illustration of why line balancing and constraint analysis drive real ROI on a production floor.Under the hood the stack is modern. The Teguar IPC runs Ubuntu with Portainer managing containers for Ignition 8.3, Ignition 8.1, and a MariaDB database for alarm history. Ignition 8.3 ships new drivers for Rockwell, Siemens, Mitsubishi, and Omron controllers along with OPC and MQTT, and each asset carries ten randomized faults written in both Ignition and PLC logic. Vlad built it for everyone from engineers to the decision makers running SCADA and MES projects. Dave and Vlad will also shoot content at the Siemens booth on Tuesday and the Horner Automation booth on Wednesday, and Dave is moderating a Wednesday session on software defined automation and the factory of the future.Timestamps0:00 Welcome and Automate 2026 preview1:50 First timer tips and arriving early for registration3:10 Networking events worth attending: A3 and Manufacturing Champions4:40 Building a trade show checklist to maximize your time7:00 Manufacturing Hub at the Siemens and Horner booths9:50 Vlad's live production line demo at the Teguar booth15:40 The line overview screen and five packaging assets17:30 Fault handling and finding the bottleneck20:10 Inside the stack: Ubuntu, Portainer, Ignition, MariaDB23:50 Random fault simulation and PLC driver options27:00 Who should come see the demo29:40 Vendors Vlad is tracking and closing thoughtsReferencesAutomate 2026: https://www.automate.orgIgnition by Inductive Automation: https://inductiveautomation.comHorner Automation: https://hornerautomation.comAbout Your HostsVladimir Romanov is a co-host of The Manufacturing Hub Podcast and the founder of Joltek, an independent manufacturing and industrial automation consulting firm specializing in modernization strategy, digital transformation, and workforce development. Joltek works with manufacturers and investors to de-risk modernization and build the internal capability to sustain results.Connect with Vlad: https://www.linkedin.com/in/vladromanov/Want to go deeper? Vlad and the team at Joltek have covered related topics here:Connecting an Allen Bradley PLC to Ignition: https://www.joltek.com/blog/connecting-allen-bradley-plc-ignitionManufacturing Line Speed Optimization: https://www.joltek.com/case-study/manufacturing-line-speed-optimizationDave Griffith is a co-host of The Manufacturing Hub Podcast and founder of Capelin Solutions, an industrial automation firm helping manufacturers adopt smart manufacturing technology. He brings 15 years of experience in industrial automation and digital transformation.Connect with Dave: https://www.linkedin.com/in/davegriffith23/Subscribe to Manufacturing Hub: https://www.manufacturinghub.liveLinkedIn: https://www.linkedin.com/company/manufacturing-hub-networkYouTube: https://www.youtube.com/@ManufacturingHub

In this episode of Manufacturing Hub, Vlad Romanov and Dave Griffith sit down with David for a practical, operator grounded conversation about industrial data, modernization, and what it actually takes to turn plant floor signals into business decisions. David has spent more than two decades in manufacturing across automotive, solar, and electric vehicles, and his story is a familiar one for a lot of us. He walked into a plant thinking he was there for a project, discovered PLCs in real time, and never left the factory world. From early days wiring up a SQL Server to pull line data instead of sending people out with stopwatches, to leading data and analytics and shaping MES and reporting strategy, this conversation stays focused on the messy middle where most factories live.A big theme here is that collecting data is not the same thing as creating information. As tooling has improved, connectivity, historians, SCADA, cloud storage, MQTT, and the modern ecosystem have made it easier to get signals out of machines. The hard part is deciding what matters, aligning stakeholders, and creating context that survives across teams and projects. David breaks down how real progress often starts with simple visibility, what is ruining your day, what is the biggest safety risk, what is the recurring quality miss, what is the downtime story you do not trust, then builds from there using workshops and iterative delivery instead of giant multi year “boil the ocean” programs.We also get into Unified Namespace, why it resonates with people who have been burned by tightly coupled ISA style integrations, and why change management is the hidden cost. If you are exploring UNS, this episode highlights the difference between drawing the box on a whiteboard and getting a whole organization to actually adopt consistent naming, context, and ownership. Then we finish with a grounded take on industrial AI. No hype, no doom. Just a realistic view of where AI helps today, where it breaks, and why context windows, documentation quality, and domain expertise still decide whether results are useful or dangerous.Timestamps00:00:00 Welcome and the month theme on technology modernization00:02:10 David’s background from automotive and the Tesla Fremont NUMMI era to data leadership00:05:10 The moment data became “real” and why proactive visibility drives safety and outcomes00:07:10 How Kaizen and Toyota Production System style problem solving creates demand for data00:11:50 Why modern tooling makes collection easier and why budget and commitment still decide success00:16:10 Starting points that work in the real world and the simplest visibility model that scales00:18:20 Unified Namespace explained through decoupling, context, and why the first attempt often fails00:23:50 Who really uses the data, operators, quality, engineering, and the “next factory” teams00:29:10 Defining KPIs when nobody has answers and using workshops to force prioritization00:34:20 What rollouts actually take, machine states, data structures, controls changes, and iteration00:40:10 Industrial AI reality check, where it helps today and why it is not running your factory00:51:10 Predicting the next few years, consolidation, pricing, and better integration with agentsAbout the hostsVlad Romanov is an industrial automation and manufacturing leader with over a decade of plant floor experience across major manufacturers. He is the founder of Joltek, where he helps teams modernize operations through IT and OT architecture, integration, reliability focused execution, and practical upskilling that actually sticks. Joltek works with manufacturers who need real outcomes, not buzzwords, and the work spans controls, data, networking, and operational performance.Dave Griffith is the co host of Manufacturing Hub and works at the intersection of manufacturing operations, technology modernization, and practical delivery. He focuses on helping teams bridge the gap between “we want data” and “we can run this plant better next quarter.”About the guestDavid has 25 plus years of manufacturing experience spanning automotive, solar manufacturing, and EVs. He started in plant floor automation and conveyance projects, then moved deeper into industrial data, MES, and analytics leadership. His recent work includes leading data and analytics, defining KPI strategy, and building the layers required to turn raw plant signals into usable business information.Links from Joltekhttps://www.joltek.com/blog/mastering-unified-namespace-uns-a-guide-to-data-driven-manufacturing-transformationhttps://www.joltek.com/blog/ultimate-guide-mqtt-manufacturingSubscribe for more conversations on manufacturing modernization, industrial data architecture, MES realities, and what works on the plant floor when the budget, people, and legacy systems are all real.

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.

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/

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 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...