Ctrl+Alt+Mfg Podcast

In this episode of Ctrl+Alt+Mfg, Josh Peeno, P.E., joins the conversation to explore why so many digital transformation and AI initiatives in manufacturing fall short. It’s not because the technology isn’t powerful; it’s because it often isn’t built for the realities of the plant floor. Drawing on his experience in heavy manufacturing and industrial AI, Peeno explains why successful transformation requires operator trust, practical deployment strategies and a deep understanding of how factories actually run. Peeno also discusses the concept of “machine teaching,” using human expertise to train autonomous AI systems in a way that supports operators rather than replaces them. He shares lessons from applying AI in glass manufacturing, talks about the value of fractional technical leadership for mid-sized manufacturers and explains why the industry’s looming skills gap may be one of the biggest drivers for smarter automation. Chapters (00:00:00) - The Reality of AI in Manufacturing(00:04:55) - Understanding Digital Transformation Challenges(00:09:05) - Bridging the Gap in Manufacturing(00:14:36) - The Human Element in Digital Transformation(00:18:34) - AI: Fear and Resistance on the Plant Floor(00:21:23) - AI as the Apprentice in Manufacturing(00:30:43) - Fractional Leadership: A New Approach(00:33:35) - Teaching the Next Generation of Engineers(00:35:50) - Global Competitiveness in Manufacturing

In this episode of Ctrl+Alt+Mfg, Gary Cohen and Stephanie Neal sit down with John Dyck, CEO of CESMII, and John Harrington, chief product officer at HighByte, to talk about why interoperability is one of the biggest barriers to smart manufacturing. As manufacturers invest in connected systems, cloud platforms, analytics and AI, many are still struggling to turn that technology into real business value because their data remains trapped in silos. Dyck and Harrington explain why interoperability has become more than just a technical challenge, how legacy systems and one-off integrations have slowed progress and why a more open, standardized approach is critical for scaling digital transformation across the enterprise. The conversation also dives into CESMII’s Industrial Information Interoperability Exchange (i3X), the role of collaboration between manufacturers and software providers and why interoperability could be the foundation for the next generation of industrial AI. Chapters (00:00:00) - The Importance of Interoperability in Manufacturing(00:04:20) - Introduction to Smart Manufacturing Institute(00:10:55) - Understanding Smart Manufacturing vs Digital Transformation(00:12:33) - High Byte's Role in Data Integration(00:18:01) - Challenges of Data Silos in Manufacturing(00:20:03) - Industrial Information Interoperability Exchange Initiative(00:21:24) - Collaboration Among Competitors(00:23:11) - Integrating Industrial Data(00:24:59) - Advancements in Specification Implementation(00:26:47) - The Importance of Abstraction in Technology(00:29:09) - Shifting Mindsets in Technology Providers(00:30:37) - Ecosystem of Specialists in Manufacturing(00:33:09) - AI's Role in Scaling Manufacturing Operations(00:34:35) - An Inflection Point in Manufacturing Innovation(00:36:27) - Interoperability as an Accelerator(00:38:47) - The Future of Smart Factories(00:45:00) - The Human Element

What’s really holding manufacturers back from smarter maintenance? While many point the finger at AI or automation, bad data might be the real culprit. In this episode of Ctrl+Alt+Mfg, Gary Cohen and Stephanie Neil talk with Paul Ross of Limble and Ross Fergerson of RBC Bearings about why so many plants are still stuck in reactive maintenance mode and what it takes to move toward more proactive, data-driven operations. They explore the maintenance maturity curve, the role of modern CMMS platforms and why technician-friendly tools are essential for adoption. Fergerson also shares how RBC Bearings replaced a legacy system and rolled out a new CMMS in just eight months, improving visibility, reducing paperwork and building trust across the organization. The conversation looks at how better maintenance data can preserve tribal knowledge, improve planning and make AI more practical on the plant floor. Chapters (00:00:00) - Introduction to Smarter Manufacturing(00:03:44) - The Importance of Maintenance Data(00:07:32) - Understanding CMMS and Its Role(00:11:41) - Transitioning from Legacy Systems(00:18:12) - Accelerating Adoption of New Technologies(00:20:23) - The Role of AI in Maintenance(00:23:00) - Addressing Common Maintenance Challenges(00:27:04) - Transforming Maintenance from Cost Center to Profit Center(00:28:52) - Operational Changes Post-Implementation(00:31:59) - Advice for Modernizing Maintenance

In this episode of Ctrl+Alt+Mfg, Gary Cohen and Stephanie Neil talk with Adrienne Meyer, CEO of the Control System Integrators Association (CSIA), about why system integrators are becoming more essential than ever in modern manufacturing. As companies push ahead with AI, digital transformation, robotics and smarter automation, integrators are the ones connecting systems, software and operations to make those investments actually work. Meyer shares how the role of the system integrator is evolving beyond traditional controls work into data-centric, networked and AI-aligned solutions. She also discusses the biggest trends shaping the market right now, including workforce shortages, brownfield upgrades, cybersecurity demands and the growing opportunities in data centers, semiconductors and defense. The conversation also looks at the value CSIA brings to the integration community, why collaboration remains so important in a competitive market and what attendees can expect from the 2026 CSIA Conference in Baltimore. Chapters (00:00:00) - System Integrators: Driving the Future of Manufacturing(00:07:01) - Meet Adrienne Meyer: New CEO of CSIA(00:09:50) - The Role of CSIA and System Integrators(00:17:47) - Current Trends and Opportunities in System Integration(00:22:34) - Upcoming CSIA Conference Highlights(00:25:41) - Navigating Change in System Integration(00:30:02) - Addressing Workforce Shortages and AI Adoption(00:31:49) - Technological Opportunities and Disruptions(00:35:58) - Closing Thoughts and Future Directions

Manufacturing may be stabilizing but its workforce is at a turning point. In this episode of Ctrl+Alt+Mfg, Amara Rozgus, editor-in-chief of Plant Engineering, breaks down insights from the 2026 Plant Engineering Salary Survey. The data shows a highly experienced, well-paid and satisfied workforce, but one that’s rapidly nearing retirement, with too few junior engineers coming up behind them. We discuss the growing skills gap, declining entry-level salaries, the risk of institutional knowledge loss and how AI is being viewed on the plant floor. Is it a helpful tool or a potential threat? If you’re thinking about workforce strategy, digital transformation or the future of manufacturing talent, this episode is for you. Chapters (00:00:00) - Introduction to Manufacturing Challenges(00:01:29) - Stephanie Gets Catfished Over a Dog(00:05:12) - The State of the Plant Engineering Workforce(00:07:12) - Insights from the 2026 Salary Survey(00:10:25) - The State of Manufacturing Engineering(00:15:15) - The Aging Workforce and Skills Gap(00:23:13) - The Role of AI in Manufacturing(00:27:08) - Conclusion and Future Outlook

Digital transformation remains a top priority for manufacturers, but many initiatives still stall between strategy and execution. In this episode of Ctrl+Alt+Mfg, Dan Furrow, senior vice president and general manager, U.S. industrial, global accounts and international markets, at Wesco, and Luis Atencio, solutions architect for Wesco’s smart manufacturing team, join the podcast to explore what separates modernization from true digital transformation. They discuss: Why modernization is only the foundation How data silos undermine enterprise-wide visibility The importance of orchestration when integrating hardware, software and systems How AI can support workforce continuity and reduce unplanned downtime Why successful initiatives begin with business outcomes, not technology trends With real-world examples and practical best practices, this episode provides a grounded look at how manufacturers can unlock value from the data they already have. Chapters (00:00:00) - Introduction to Digital Transformation in Manufacturing(00:05:37) - Understanding Modernization vs. Digital Transformation(00:10:12) - The Role of Friction in Transformation(00:14:57) - Breaking Down Silos in Manufacturing(00:18:30) - The Importance of Orchestration(00:20:44) - Data as a Critical Asset(00:25:07) - Real-World Applications of Data Integration(00:29:21) - Common Themes in Successful Projects(00:32:31) - Best Practices for Manufacturers(00:34:55) - Conclusion and Key Takeaways

Cybersecurity threats are no longer confined to IT systems. They’re now crossing into the physical world, with real consequences for manufacturing, supply chains and critical infrastructure. In this episode of Ctrl+Alt+Mfg, hosts Gary Cohen and Stephanie Neil are joined by Ian Bramson, vice president of global industrial cybersecurity at Black & Veatch, to unpack what this shift means for industrial organizations. The conversation explores why the industrial attack surface is expanding, how supply chains and legacy systems create hidden vulnerabilities and why cybersecurity needs to be built in early through concepts like clean build, not bolted on after startup. Bramson also dives into how attackers are using AI, what “AI vs. AI” means for defenders and the unique challenges of securing OT environments as operations move to the cloud. HIs takeaway is to keep it simple, start early and focus on building a resilient cybersecurity foundation that can adapt as technology — and threats — continue to evolve.   Chapters (00:00:00) - Introduction to Cybersecurity in Manufacturing(00:05:47) - The Growing Threat of Cyberattacks(00:09:25) - Evolving Cybersecurity Landscape(00:13:34) - The Concept of Clean Build(00:17:43) - Supply Chain Vulnerabilities(00:23:06) - AI in Cybersecurity: Opportunities and Threats(00:27:04) - Cloud Security Challenges(00:29:47) - Final Thoughts and Key Takeaways

Automation is no longer optional, but where should manufacturers invest to see real returns? In this episode of Ctrl+Alt+Mfg, we’re joined by Mark Hoske, editor-in-chief of Control Engineering, to break down the findings of the 2026 State of Industrial Automation Report. We discuss where automation is delivering measurable ROI, why advanced process controls continue to lead, how manufacturers are balancing efficiency with risk and what year-over-year data reveals about changing adoption trends. The conversation also explores workforce challenges, skills gaps and how automation is being used to create higher-skill roles rather than replace workers. If you’re specifying, implementing or justifying automation investments, this data-driven episode cuts through the hype to focus on what’s actually happening on today’s plant floors. Chapters 00:00 Introduction to Automation and Manufacturing Trends 08:58 Insights from the 2026 State of Automation Report 18:19 Key Findings and Surprises in Automation Investments 21:42 Emerging Technologies in Automation 23:41 Insights from the 2025 State of Automation Report 24:52 Looking Ahead: The 2026 Automation Report 27:25 The Importance of Community in Automation Research 28:53 Future Trends and Research in Automation 31:03 Connecting the Dots: Automation and Community Engagement   Chapters (00:00:00) - Introduction to Automation and Manufacturing Trends(00:08:58) - Insights from the 2026 State of Automation Report(00:18:19) - Key Findings and Surprises in Automation Investments(00:21:42) - Emerging Technologies in Automation(00:23:41) - Insights from the 2025 State of Automation Report(00:24:52) - Looking Ahead: The 2026 Automation Report(00:27:25) - The Importance of Community in Automation Research(00:28:53) - Future Trends and Research in Automation(00:31:03) - Connecting the Dots: Automation and Community Engagement

What if you could test changes to your manufacturing process without risking downtime, scrap or costly mistakes? In this episode of Ctrl+Alt+Mfg, hosts Gary Cohen and Stephanie Neal are joined by Matt Wise, CEO of E Tech Group, and Cole Switzer, principal full stack developer and head of advanced software, to break down the real-world impact of digital twins in modern manufacturing. The conversation goes beyond buzzwords to explain what a digital twin actually is, the different types—from simulation and data twins to live visual twins—and how manufacturers are using them today across pharma, life sciences, food & beverage, CPG, energy and data centers. Matt and Cole explore why a strong digital backbone and unified namespace are critical to success, how digital twins are enabling faster ROI and AI readiness and what it really takes to scale these technologies across multi-site, global operations. They also discuss the path toward remote monitoring, predictive optimization and even the long-debated lights-out factory. Whether you’re early in your digital transformation journey or looking to take the next step, this episode offers practical insight into how digital twins are reshaping manufacturing—now and into the future. Chapters (00:00:00) - Introduction to Digital Twins in Manufacturing(00:04:47) - E Tech Group's Journey and Client Expectations(00:11:57) - Understanding Digital Twins: Definitions and Types(00:17:43) - Challenges in Scaling Digital Twins Across Multiple Sites(00:20:09) - Measuring ROI with Digital Twins(00:25:26) - Creating a Sustainable Digital Twin Model(00:26:55) - The Future of Lights Out Facilities(00:28:34) - The Role of Backgrounds in Digital Twin Development(00:31:08) - Company Culture and Continuous Learning at E Tech Group

As 2025 winds down, Ctrl+Alt+Mfg is taking stock of what actually mattered in manufacturing this year. In this year-end special, hosts Gary Cohen and Stephanie Neil are joined by Mike Ouellette, senior editor at Engineering.com, to unpack the real state of digital transformation on the plant floor—beyond the buzzwords. They dig into: Why digital transformation isn’t new, and how today’s wave differs from past eras of automation. Where AI is already delivering value in manufacturing (and why AI agents trained on your own data are such a big deal). How digital twins, robotics, cloud ERP/MES/PLM and edge devices are changing everyday operations. The skills engineers and operators need now that roles are shifting from “do the task” to “interpret the insights.” Why so many initiatives get stuck in “pilot purgatory” and how small wins can fund the next project. Underrated cybersecurity risks in smart factories, especially around legacy equipment and the IT/OT divide. The technologies Mike believes will really move the needle in the next 3–5 years. If you’re trying to separate digital transformation hype from what’s actually working—and know where to focus in 2026—this episode is your year-end reality check. More from us: Control Engineering: ControlEng.com Engineering.com: Engineering.com CHAPTERS 00:00 Reflecting on Manufacturing Trends of 202506:37 Understanding Digital Transformation in Manufacturing10:40 The Evolution of Technology in Manufacturing15:08 Identifying Value in Digital Transformation18:38 Skills for the Future of Manufacturing22:01 AI's Role in Augmenting Human Work24:50 Challenges in Digital Integration and ROI25:07 Navigating Pilot Purgatory in Manufacturing29:34 The Importance of Data in Digital Transformation30:30 Capturing Tribal Knowledge for Future Success31:57 Cybersecurity Challenges in Smart Factories35:05 Emerging Technologies Shaping the Future42:05 Evaluating the Promise of Digital Transformation Chapters (00:00:00) - Reflecting on Manufacturing Trends of 2025(00:06:37) - Understanding Digital Transformation in Manufacturing(00:10:40) - The Evolution of Technology in Manufacturing(00:15:08) - Identifying Value in Digital Transformation(00:18:38) - Skills for the Future of Manufacturing(00:22:01) - AI's Role in Augmenting Human Work(00:24:50) - Challenges in Digital Integration and ROI(00:25:07) - Navigating Pilot Purgatory in Manufacturing(00:29:34) - The Importance of Data in Digital Transformation(00:30:30) - Capturing Tribal Knowledge for Future Success(00:31:57) - Cybersecurity Challenges in Smart Factories(00:35:05) - Emerging Technologies Shaping the Future(00:42:05) - Evaluating the Promise of Digital Transformation

Why do so many MES and industrial software projects fail and how can manufacturers finally fix the problem? In this episode, Gary Cohen and Stephanie Neil talk with Ryan Crownover, director of digital plant at Vertech, about why industrial software shouldn’t be treated as special and how adopting agile, iterative development can dramatically improve ROI and user adoption. We dig into: • What manufacturers really need from MES and digital plant systems • Why cloud outages expose gaps in resilience • How to avoid “boiling the ocean” with over-scoped projects • The value of operator feedback and user-centered design • Vertech’s Momentum Method for faster, lower-risk deployments If you’re building or modernizing industrial software, this conversation offers practical, real-world guidance to help your projects succeed. Chapters (00:00:00) - Why the Cloud Is Threatening Manufacturing Software(00:06:21) - What's the Need for Software in Digital Transformation?(00:07:35) - Interview: The Director of Digital Plant at Vertec(00:08:38) - Software Productivity: Manufacturing Innovation(00:17:38) - Intelligence: Is Industrial Software Unique?(00:20:21) - What's The Lean Startup Code?(00:23:11) - How to Build a User Experience(00:25:45) - Vertech's 'Momentum' Process(00:28:18) - Challenges to Transition to an Agile Approach(00:30:27) - What kind of feedback are you getting from your clients?(00:32:27) - D3.8: Digital Plant Journey(00:33:42) - Small Incremental Changes in Manufacturing Software

Digital transformation is everywhere — but what does it really mean for manufacturers? In this episode of Ctrl+Alt+Mfg, hosts Gary Cohen and Stephanie Neil sit down with Alicia Lomas, founder of Lomas Manufacturing, to talk about the practical side of Industry 4.0. From connecting data and building smarter control rooms to bridging IT and OT teams, Alicia explains how real transformation starts with context, collaboration, and curiosity. Learn how AI fits into today’s factories, why “context is king,” and what it takes to make digital transformation actually work. #Manufacturing #Automation #DigitalTransformation #ControlEngineering #AI #Industry40 #Podcast Chapters (00:00:00) - resetting and rethinking manufacturing(00:01:48) - AI's Future of the Control Room(00:06:06) - Controls Engineers: The Right Time for Digital Transformation(00:08:50) - Controls Engineers: The Digital Transformation Challenge(00:14:06) - I Sneaked In a Historian or Data Logging(00:16:19) - What Does Digital Transformation Mean to the Plant Floor?(00:20:06) - Control & IT: The Unified namespace(00:26:38) - What is the first thing that you would have done differently on a(00:29:02) - Getting out there in the controls world(00:30:57) - Alicia on Being a Leader in Manufacturing(00:36:30) - Lomas Manufacturing Consulting

Cybersecurity isn’t just an IT issue — it’s a manufacturing issue. In this episode of Ctrl+Alt+Mfg, hosts Gary Cohen and Stephanie Neil talk with Leah and Jeremy Dodson, co-founders of Piqued Solutions, about the evolving threats facing operational technology (OT) environments. From the myth of the “air gap” to the rise of AI-driven defenses, the Dodsons explain why factories must rethink security and move from perimeter protection to layered resilience. They share real-world insights on cyber hygiene, protecting critical data and building a culture where security enables innovation instead of blocking it. Topics covered: Why default credentials and legacy systems are still major risks The end of the “air gap” and what layered security really means How AI can help — and hurt — OT cybersecurity The importance of culture and “cyber champions” on the plant floor Subscribe for more conversations about people, technology, and strategies reshaping the future of manufacturing. #Cybersecurity #Manufacturing #IndustrialSecurity #OTsecurity #DigitalTransformation #ControlAltManufacturing Chapters (00:00:00) - Introduction to Cybersecurity in Manufacturing(00:02:40) - The Rising Threat of Cyber Attacks(00:05:33) - Understanding Operational Technology (OT) Security(00:08:21) - The Role of Ethical Hacking(00:11:35) - Challenges in Cyber Hygiene(00:14:23) - The Myth of Air Gaps(00:17:36) - Data Protection vs. Access Control(00:20:23) - Innovative Cybersecurity Strategies(00:23:34) - The Impact of AI on Cybersecurity(00:26:35) - Risks Associated with AI in Cybersecurity(00:28:51) - Adopting AI in Industrial Security(00:32:53) - DevSecOps in Industrial Control Systems(00:39:30) - Cultural Shifts for Cybersecurity Awareness(00:42:15) - Empowering Innovation in Cybersecurity(00:43:59) - Insights from Mr. Robot

In this episode of Control Alt Manufacturing, hosts Gary Cohen and Stephanie Neil sit down with John Lee, senior manager of manufacturing intelligence at Matrix Technologies, to explore how manufacturers can connect data from legacy systems, automate securely and prepare for the rise of AI on the plant floor. John shares how companies are tackling the challenge of disparate data, why data integrity is critical for AI and analytics and how protocols like MQTT and OPC UA are transforming connectivity. He also explains why human expertise still matters—even in an era of automation and predictive maintenance. How to build data trust The role of system integrators AI, machine learning, and the future of manufacturing *** If you like this podcast, get more episodes at controleng.com or ctrlaltmfg.castos.com. Chapters (00:00:00) - Introduction to digital transformation in manufacturing(00:02:18) - The role of AI in manufacturing(00:05:09) - Understanding manufacturing intelligence(00:08:12) - Challenges of disparate data(00:11:00) - Cybersecurity in manufacturing(00:14:00) - Data integrity and reporting(00:17:14) - Real-time decision making(00:20:15) - Predictive maintenance and AI(00:23:14) - Customer journeys in digital transformation(00:26:05) - The future of AI in manufacturing

Ctrl+Alt+Mfg publishes new episodes every two weeks and is available on ControlEng.com and major podcast platforms. The opening episode, “Resetting and Rethinking Manufacturing,” introduces the show’s themes and shares highlights from WTWH Media’s 2025 automation research. Hosted by Gary Cohen and Stephanie Neil.  *** If you like this podcast, get more episodes at controleng.com or ctrlaltmfg.castos.com. Chapters (00:00:08) - Rebalancing & Rethinking Manufacturing(00:03:03) - The future of automation is digital transformation(00:05:02) - In the Elevator With Automation Pros(00:06:01) - What is Digital Transformation for Manufacturing?(00:10:29) - The State of Industrial Automation Report(00:16:50) - The STEM workforce gap(00:24:29) - Packaging OEM: Automation and sustainability(00:26:44) - Free Report on the Future of Research(00:27:03) - Welcome to Control Engineering Podcast #1(00:28:41) - C Ctrl Alt Manufacturing Podcast