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.

• (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.

• (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.

• (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

• (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.

• (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 2025
06:37 Understanding Digital Transformation in Manufacturing
10:40 The Evolution of Technology in Manufacturing
15:08 Identifying Value in Digital Transformation
18:38 Skills for the Future of Manufacturing
22:01 AI's Role in Augmenting Human Work
24:50 Challenges in Digital Integration and ROI
25:07 Navigating Pilot Purgatory in Manufacturing
29:34 The Importance of Data in Digital Transformation
30:30 Capturing Tribal Knowledge for Future Success
31:57 Cybersecurity Challenges in Smart Factories
35:05 Emerging Technologies Shaping the Future
42:05 Evaluating the Promise of Digital Transformation

• (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.

• (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

• (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