Gary On Manufacturing - Gary Mintchell

This podcast is sponsored by Inductive Automation. Two topics dominated my inbox this year--and will probably continue to do so. These are AI Large Language Models and Cybersecurity. 

Looking at Google v DOJ and Apple v EU, Gary draws lessons for industrial automation.

Many times in my career I have hired into a company during the initial surge of a market. Good jobs. Excitement. Opportunity to work on new things. Then the market matured or collapsed usually due to external forces such as technology changes or consumer behavior.   I hit recreation vehicles at a high point followed by high inflation and gasoline price surges. Then a consumer product company where Consumer Reports published a poorly researched article—but the external market also changed. Then PC peripherals. The latest was automation where a few of us started a magazine to cover it. The market was good for about 10 years. Then we went into brief cycles of IIoT, edge, networks, collaborative robots, IT companies looking at the manufacturing market.   This podcast began life in 2007 as Automation Minutes. I morphed it into Gary on Manufacturing to make it more general. That was more than 10 years ago. Must be time for another change.   That all is quite mature now.    Where do you think the offsetting new technologies or customer behavior will lead now? Or, is the market just going to begin to either consolidate further or split? What do you think?

Gary offers observations on the continuing saga of former GE executives running Boeing changing the culture from engineering-driven to Wall Street-driven. Also thoughts on good manufacturing leadership.

Gary discusses the current state of the automation and control market. Why it seems to be a stable market and why the media in the market are shrinking. He riffs from Seth Godin blog  The Drift to Normal. As an organization grows in scale, the idiosyncrasy and distinctiveness that was originally informed by the taste of the founders moves toward the mean. Over time, things get more average. I have arranged a special deal with energy drink makers Magic Mind. Listeners can visit https://www.magicmind.com/garym and get up to 56% off your subscription for the next 10 days with my code GARYM20. After 10 days, you can still get 20% off for one time purchases and subscriptions.  My sponsor is Inductive Automation. Check out their flagship product Ignition and the Cloud and Edge editions. If you would like to get a message out to about 200,000 people, you, too, could be a sponsor. Reply to this email to find out more about sponsorship opportunities.

Gary discusses productivity, slow productivity movement, busyness or pseudo-productivity. Sponsors Inductive Automation inductiveautomation.com and Magic Mind, magicmind.com/garym and use code GARYM20.

I've seen successes of industry standards. I've also seen industrial standards struggle to break through the logjam of large companies drive to lock customers into their ecosystem. What is the latest of OPAF and what is the meaning of Schneider Electric's announcement of a product built with with Red Hat and IBM and development of a new computer communication standard? I have arranged a special deal with energy drink makers Magic Mind. Listeners can visit https://www.magicmind.com/garym and get up to 56% off your subscription for the next 10 days with my code GARYM20. After 10 days, you can still get 20% off for one time purchases and subscriptions. That's magicmind.com/garym with the code GARYM20. This podcast is sponsored by Inductive Automation. https://www.inductiveautomation.com

Boeing is a company that has lost its way. I have no idea why the board has not sacked the CEO. The 737MAX  program was a fiasco and continues to haunt the company. The 787 program ran way behind schedule costing the company billions. This is what happens when you ignore product and serving customers instead focusing solely on financial numbers. We are a business company not an engineering company, said one Boeing CEO. How right he was. They can't build an airplane anymore. But they can still count, I guess.

Gary gives leadership growth tips based on Dan Lyons "The Power of Keeping Your Mouth Shut in an Endlessly Noisy World" and David Brooks "How to Know a Person: The Art of Seeing Others Deeply and Being Deeply Seen."

Gary discusses how listening and conversations are vitally important to leadership using books by Dan Lyons, STFU, and David Brooks, How to Know a Person.

After attending several technology supplier user conferences this summer and fall, a colleague asked why suppliers are emphasizing software. I ponder this question in this podcast essay. And ask what the new breed of engineers will bring with new ideas. Maybe Arduino control platforms? Worth asking.

Do digital tools have the effect of adding more things to our plate rather than helping us get things done? Gary looks at how software helped him get productive and then seemed to bog down and still accomplish a lot, but it seems slower over all. Even more, what is more important—getting more done or doing what is impactful?

My career spans the innovation to maturity cycle of three technology markets--PC, IT, Automation. I wonder what's next.

I went to this year's Honeywell User Group with many questions. They were all answered as you will hear. There were many questions begging for answers as I traveled to Florida. What was Honeywell HIVE, and how does it relate to the ExxonMobil initiated Open Process Automation group? What is Honeywell Digital Prime and what customer problems does it address? What successes have Honeywell achieved with sustainability initiatives? Honeywell was an early mobility developer. What has progressed in that regard? What role does Honeywell see for AR and VR?

Gary talks about the successful integrations of software by Siemens since the 2007 acquisition of UGS. He reflects on early conversations with Siemens executives regarding the Digital Factory and then how far the company has traveled along that path becoming perhaps the most successful industrial automation and industrial software supplier.

Surveying the past of automation and control tech and the tech media market over the years, then taking a look at future coverage for Gary on Manufacturing and The Manufacturing Connection.

Observations, thoughts, questions about automation and control market, the companion media market, and innovation. Thoughts welcome.

I presented a Webinar on April 5. You can find it here https://www.manufacturingtechnologytoday.com/frs/23189866/going-beyond-digital-transformation--the-real-innovations-in-manufacturing/email . I talked about how digital data isn't new, my 1978 project, how we need to watch for disruption coming from anywhere, the importance of people, and how you, yes you, can and should be a change agent.

Why is it that open systems work in IT and not OT. The work of the Open Process Automation Forum.

Update on the industrial metaverse essay and podcast given the Google, Facebook, and Microsoft news to AI, ChatGPT, and search ads. Thoughts on merger and acquisition including new thoughts on Emerson bid for NI. Finally, a new take on video for manufacturing. Sponsored by Ignition from Inductive Automation.

Yes, I'm back after a long hiatus due to some projects that soaked up my time. Metaverse remains the hot topic in industrial technology discussion circles. Are we getting closer to reality than what I spoke of in episode 241? There are some interesting new concepts from both Rockwell Automation and GridRaster plus others.

Press releases come to me from a variety of sources. The topics are often in batches. There was 3D printing, then cybersecurity, now sustainability. Check out a new book instigated by Seth Godin (check his podcast out at akimbo.link) called The Carbon Almanac (thecarbonalmanac.org). Electric is big, as in electric cars. Everything needs big engineering ideas. What will you contribute?

Two developers reflecting on Apple's Worldwide Developer's Conference in terms of Gartner's Hype Cycle--about getting enthused at the event and then reality settling in when the amount of work is realized. I reflect on the several trips I made in May and June in the same model. I'm not saying all I got was hype, but the trip from enthusiasm to realism is worth taking.

Gary discusses 20 years of trying on headsets for manufacturing applications. Is the Metaverse finally upon us? Probably not.

Perhaps if President Nixon had read 500 books rather than watching 500 movies during his time in office... What happened to all the free time we were supposed to get from increased productivity? Oliver Burkeman discusses time management in Four Thousand Weeks. And no, it's not a new system. Plus Karels and Miller wrote Steel Toes and Stilettos, a story of Lean Transformation of three manufacturing plants. It's The Goal for a new generation.

There was Internet of Things, IoT, then Industrial Internet of Things, IIoT, and companies formed groups to build product and exploit the area. Then they went away. What happened? What's new? Taking a look at data orchestration and data ops.

Gary discusses how to answer why spend the money, how we learned to build safety into machines and processes, and how we'll learn to do the same with cybersecurity.

Gary recaps the recent ODVA annual general meeting. Keynoter Paul Maurath of P&G corporate engineering discussed laboratory testing of EtherNet/IP with APL. He asked for more configuration and device description help. ODVA tech group engineers have been very busy with OPC UA mapping, TSN, and CIP for discrete devices. It was great to meet again.

Gary discusses ideas around corporate sustainability and looks at what three automation companies are doing--ABB, Rockwell Automation, and Schneider Electric.

Gary ponders the state of the automation and control market riffing off the ARC Advisory Group / Control Global Top 50 by sales. Is this a mature market? New entrants seem to be acquired by incumbents as an innovation strategy by the larger companies. What does a mature market mean?

How are your New Years Resolutions coming? Quit already? Try a few tips from Gary about improving life and career this year.

I love irony. Like when people click on my consulting link and want to sell me consulting instead of asking me to consult. Also a quick trip around the Fabtech and Additive Manufacturing Trade Show, the size of The Manufacturing Connection--your number one resource. Sponsored by Ignition by Inductive Automation.

Rick Bullotta posted a provocative comment on LinkedIn predicting a shakeup in the industrial software business with the hyperscaler cloud companies acquiring a chunk of those now owned by OEMs or the few independent ones. I've thought about this for a long time. What do you think?

231 Are You Being Served? While thinking about the proliferation of as-a-service models of business, thoughts of that 70s and 80s British comedy TV show came to mind. Are you being served? Proved feasible by Salesforce and then adopted by many including recently HPE as the strategy for the entire company, we are witnessing automation companies exploring the as-a-service business model. I wonder how far it will go.

230 AR and VR AR, MR, VR, XR--what R we supposed to make of all this technology. We've been playing with the idea for more than 20 years when I first reported on a new product that promised to connect a line technician with a remote expert (using video camera) and show work instructions (augmented reality). At the time legendary blogger Robert Scoble in 2013 or so predicted we'd all be wearing Google Glass. That device would tell us whom we were about to meet on the street so that we could greet them by name and ask relevant questions. The immersive experience of visual reality is great for gamers and perhaps for operator and maintenance training. This technology is here, just unevenly distributed.

229 Flying in the Clouds A beginning student pilot must only fly on clear days where the ground is always visible. Following much additional training, the student can achieve instrument rating and can "fly in the clouds." Manufacturing and production companies are moving to flying in the clouds perhaps much more quickly than they moved to any other technology. Of course, I'm talking about cloud computing. I recently sat in the ROKLive Rockwell Automation event. They discussed two recent acquisitions, Fiix and Plex, both of whom will move Rockwell into the cloud. Good moves. Tech doesn't change industries, says analyst Benedict Evans. People in the industry use tech to change the industry. Witness how Ethernet went from nice IT thing to a necessary network on the factory floor. Or mobile phones went from "can we control them" to "everyone has one and it changed workflows forever." Same will happen with Augmented Reality (AR). Just watch. This podcast is sponsored by Ignition from Inductive Automation. Check out Ignition 8 and the upcoming Ignition Community Conference.

Sometimes we clutter our minds with what we think we know and leave no room for learning new things. In the process, we fixate on an idea and miss the simple and most elegant explanation. I had received a news release from a manufacturing software company so full of jargon that I could barely decipher it. In the midst of the stuff was the claim that there are 40,000 IIoT professionals. Huh? I figured that they renamed engineers and technicians who wire all the field devices into a new profession. Why? Why make things more complicated than they are? The best bet is to apply Occam's Razor wherever it fits--the simplest explanation is often the best. This podcast is sponsored by Inductive Automation. Check out this year's Ignition Community Conference.

Imagine laying railroad tracks west from the US east coast and meeting up with a crew laying railroad tracks from the west coast only to discover that the width between the rails was different. Standards make a huge difference. Open standards, open APIs, and open source all enable interoperability and all make life better for users. My discussions over the past couple of years indicates that US engineers are falling behind in the encouragement and use of these technologies. I hope I'm wrong, and I hope the new generation of engineers pick up these ways of working and move American manufacturing forward. And the rest of the world, too.

Get outside. Get outside into nature, a park or something, to refresh your mind and body. Get outside your preconceived ideas and prejudices for better thinking. Mary Donelan came to KMC Systems to use Lean to improve productivity. She had to overcome existing prejudices that improvements meant reducing workforce. She exemplified the basic Lean principle of Respect for People leading personal growth along with improving productivity allowing the company to take on more work. Then I wondered about adding software and knowledge workers and any impact on productivity. This leads to considering Cal Newport's new book A World Without Email and a look at improving knowledge worker workflow. Finally, a challenge to Americans about adopting standards and productivity-enhancing methods. Thanks to long-time sponsor Inductive Automation.

According to the legend, the cup holding the wine Jesus toasted his friends with at his Last Supper the next day held some of his blood from the crucifixion. Joseph of Arimethea had possession of that cup and wound up in Britain. Whereupon it was "lost." In 1182 a poem was circulated with the story of the Holy Grail. It was bound up with the Arthur legends and then was found in a Monty Python video and later the prize of Indiana Jones (and the Last Crusade). In 1979, Dan Bricklin connected a spreadsheet for the new personal computer product, and the pursuit of the Holy Grail was transformed in the computer age to the pursuit of the killer app. We still live in the age of the pursuit of the killer app. IT companies with their IoT and Edge compute married to predictive analytics thought they found that Killer App in predictive maintenance. I think that stopping with predictive maintenance as THE app is far too shortsighted. There is far more to be gained by combining with more applications that will help make manufacturing more profitable for the enterprise.

I caught up with Tom Bradicich, PhD, VP of HPE Labs and an HPE fellow recently to get updated about Converged Edge, IoT, and bringing the Line of Business people and the CIO organization into common cause. I met Tom at NI where he was an early evangelist for data--he talked about Big Analog Data. He had come from IBM and then left NI to return to the IT world with Hewlett Packard and then with Hewlett Packard Enterprise after the split. At HPE, he led the team developing the Edgeline, a converged Edge product that brought in IoT from the OT side of the business to a powerful compute platform. Later at HP Labs led the team to develop Edge-as-a-Service, if you will, that converges LOB and CIO organizations for solving business problems.

I first heard about the world's largest manufacturing trade show, Hannover Messe, in the mid-80s when our group of VPs of a small automation company conspired to find ways for me to send the president out on meaningless sales calls. I sent him to Hannover in 1986. I have attended many times over the past 20 years. I recorded this podcast April 17 the Saturday following the 2021 digital edition of the event. Festo held the first press conference I attended flooding me with information among which were the bionic swift and its vast education initiatives. Schneider Electric talked about its Automation Expert, the answer to OPAF's quest for separating hardware and software in control. The rest of my week was primarily software as companies talked about the impact of unstructured data from IoT on industrial software.

222 Build In Resiliency How would you like to be the chief automation engineer when an automated assembly line goes down and it gets daily reports in The New York Times and the CEO camps out on the production floor until you get it fixed and that CEO is the world's smartest man--Elon Musk? Too often we build projects, automation and otherwise, without any resiliency. They are brittle. They break easily. Like the system Airbus considered with its extra-huge airliner that required every airport to upgrade runways and terminals. Or, like us, when we don't build resiliency into our careers and our lives. Even worse--the anxiety and brittleness of our children pushed to succeed above all else. Build in some resiliency in your life and go make a difference.

People hit me up continually about ability of predictive analytics for predictive maintenance as the nirvana of digital manufacturing. My reply is that digital data leads to analysis/user interface/decision support. In other words, data helps people make better decisions in order to solve manufacturing problems and run more efficient and profitable and safer plants.

"We tend to overestimate risk and under estimate value when we're evaluating digital technology implementation," stated a keynoter during the 25th annual ARC Advisory Group Forum. Another keynoter told us that if we are evaluating digital transformation initiatives using a spreadsheet, we are off base. Some things have too great a risk of not doing. A Wall Street analyst told us that over the past year industrial software companies outperformed industrial companies. Software for digital transformation is where it's at. Check out the new Schneider Electric initiative promoting software defined control based on IEC 61499. This is an outgrowth of the Open Process Automation initiative that seems to be gathering some momentum. Software is eating the world--or at least the industrial one.

219 Quality Without Wires Are you teaching quality today? That question started a young English teacher into a journey that led to the book Zen and the Art of Motorcycle Maintenance. But really, I wanted to talk about quality and wiring. I visited a prospect who was interested in a press control automation system. When I went into the plant to look at one of their presses, I saw a haphazard (and hazardous) wiring job on the control panel. I left as soon as I could. But wiring can be exceedingly expensive in many plants. Wireless became an attractive alternative. We had WirelessHart soon to be partly replaced by WiFi. Now, the latest cellular technology, 5G, when made into a private network coordinating with WiFi6, composes a powerful IoT and digital transformation communication system.

I worked with data ever since it was handwritten or typed. We can just generate much more of it these days. We can contextualize, analyze, visualize. The question is--are we using it adequately to make better decisions?

Congratulations to Eddie Habibi, Pat Kennedy, Corky Ellis, and others for building companies and getting a good exit. Where are the next generation of new companies coming from? Will they be disruptive to the manufacturing technology market? What is disruptive anyway? Podcast supported by Inductive Automation.

This podcast is sponsored by Ignition from Inductive Automation. The project engineer came to me, "We can't ship this machine, because it is not yet perfect." What is quality? When is it "good enough" to ship. What is meeting spec? When is "good enough" not sufficient?

I moved to a new state a few months ago and have been searching for a good local, independent coffee shop with ethically traded coffee--in vain. So, I go to Starbucks a few times a week. The concept of quality at Starbucks is not the coffee, which is probably why people doctor it with flavored sugars and milk. Its quality has always been environment. One of my first jobs was with Airstream, manufacturer of quality recreation vehicles. Everyone in the company was aware of the need for quality. The question for you today is are you contributing to building quality, ethical products that serve your customers and society? On a personal development note, I leave you with Seven Daily Habits from Richard Koch in The 80/20 Principle.

Manufacturing and production can be stressful occupations. Add in the constant stresses of a pandemic and there is the recipe for affecting health. Take a stress break and get a new focus.