Manufacturing Hub

• Ep. 236 - How to Deliver Manufacturing Projects That Operations Actually Use

  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

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• Ep. 235 - How to Build and Run a Systems Integration Company in Manufacturing

  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

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• Ep. 234 - What Students Learn When They Build Ignition Projects in Seventy Two Hours

  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

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• Ep. 233 - From Controls to Full-Scale Robotics Integration How Bright IA Leads in Automation

  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...

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• 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.

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