The Tool Belt

We're about a week away from Halloween, and what could be scarier than the technologies that are disrupting manufacturing—artificial intelligence and connected-worker technologies. The 4th Annual Connected Worker Manufacturing summit in the Chicago suburbs this month gathered tech leaders from dozens of large manufacturers to discuss the impacts of data tools, wearable technology, tablets and other connected devices. What does that have to do with Halloween? Well, there were a lot of food people there, including digital transformation executives at Hershey and Nestle, and we spoke to them about their efforts. Participating on this podcast are: Robert Schoenberger, editor-in-chief at IndustryWeek Logan McNear, digital manufacturing program lead for The Hershey Company's Lean Production System Mike Brauckman, head of focused improvement for Nestle

Kristianne Egbert, senior corporate ergonomist with Briotix Health, discusses the evolution of industrial ergonomics in recent years, and offers insights into how managers can cost-justify investing in ergo technologies to better protect their workers.

This episode of Great Question: A Manufacturing Podcast was recorded live at the 2025 SMRP Annual Conference, in Fort Worth, Texas. In this episode Brian Hronchek, principal trainer and consultant for Eruditio, talks with Plant Services chief editor Tom Wilk discuss how companies are using PM optimization to achieve quick, measurable improvements in both reliability and safety.

In this episode of Great Question: A Manufacturing Podcast, discover how unconventional innovations from UMass Amherst, Bluewater, and the Italian Institute of Technology are redefining sustainability across energy, water, and waste.

New York-based Arc Public Benefit Corp. bought 3D printing pioneer Desktop Metal last month out of bankruptcy. The purchased followed about two years of merger-and-acquisition mania that shifted from assigning billion-dollar valuations on equipment makers to pushing some of the same companies through bankruptcy.  Bryan Wisk, CEO of Arc, says the path to future success is clear -- focusing on running the company instead of getting caught up in the buy-sell drama of corporate mergers.  “There's only one word at DM right now internally; it's focus,” Wisk says. “We're not a distressed debt investor or private equity. We're really deep-growth investors, and we're looking to focus on the core technologies that we bought.” This Great Question episode features a conversation between Wisk and IndustryWeek Editor-in-Chief Robert Schoenberger

Mike Jones, president of Discover Leadership Training, explains why sometimes the best thing you can do to protect workers is take more risks. He explains how safety professionals can go beyond "best practices" to "next practices." And he offers a preview of his upcoming keynote presentation, "Playing It Safe," which he'll deliver at Safety Leadership Conference 2025, held October 20-22, 2025, in Glendale (Phoenix), Ariz.

Joe Kuhn, CMRP, former plant manager, engineer, and global reliability consultant, is now president of Lean Driven Reliability LLC. He is the author of the book “Zero to Hero: How to Jumpstart Your Reliability Journey Given Today's Business Challenges” and the creator of the Joe Kuhn YouTube Channel, which offers content on starting your reliability journey and achieving financial independence. In our monthly podcast miniseries, Ask a Plant Manager, Joe considers a commonplace scenario facing the industry and offers his advice, as well as actions that you can take to get on track tomorrow. In this episode, Joe how to tackle reliability and maintenance as a new manager.

Ryan Hawk of PwC US surveyed hundreds of C-suite executives across the manufacturing and energy sectors to determine what is influencing their thoughts and guiding their decision-making. He found five “unstoppable forces” reshaping how America builds, moves, and competes.

High-profile raids of manufacturing facilities by federal immigration agents are likely just beginning, labor and immigration attorney Jorge Lopez said. Increased federal funding for Immigration Customs Enforcement (ICE) agents still hasn't hit the agency and won't have a measurable impact on staffing there for months. So, expect site visits and raids to increase in Q4 of this year and especially in the first half of 2026, Lopez says. He also offers advice on how to prepare your paperwork for federal investigations, what companies are (and are not) obligated to provide and how to limit legal exposure. Speakers: IndustryWeek Senior Editor Laura Putre Littler Immigration and Global Mobility Practice Group Chair Jorge Lopez

In this episode of Great Question: A Manufacturing Podcast, Scott Achelpohl and Almog Apirion explore why IT and OT often remain misaligned and what it takes to close the gap. The discussion highlights how digital transformation, cybersecurity risks, and regulatory pressures are driving the need for convergence. Together, they examine the role of Zero Trust, identity-based access, and secure connectivity in protecting legacy equipment while keeping operations productive and resilient.

In this sponsored episode of Great Question: A Manufacturing Podcast, Plant Services chief editor Thomas Wilk sat down with Ryan Smith, a Solutions Engineer with TPC, a Certus company, whose areas of training specialty include industrial maintenance topics for electrical, mechanical, and HVAC systems. Today's great question is: How do you calculate the ROI of training?

In this episode of Great Question: A Manufacturing Podcast, Thomas Wilk and Maya Schwartz are joined by Ron Marshall, Frank Moskowitz, and Joe Ghislain to reflect on 25 years of the Compressed Air Challenge. The conversation explores the program's origins, its evolution in training methods, and its impact on system performance and energy efficiency. The group also discusses shifting industry priorities, the role of end users and vendors in training, and how new technologies are shaping the future of compressed air systems. Together, they provide insights into both the history and the next chapter of this influential industry initiative.

You may be good, but you can always be better. That's the approach Coca-Cola Consolidated has taken toward workplace safety. The publicly traded bottling company started a new safety campaign in 2024, the First 100 Days of Safety. It was so successful that Coca-Cola Consolidated expanded to three safety campaigns in 2025 and has no signs of slowing down. Dennis Padgett, senior director of risk control at Coca-Cola Consolidated, discusses what's worked and what's next with EHS Today's Managing Editor Nicole Stempak. Padgett will be speaking at Safety Leadership Conference 2025, being held from October 20-22 in Pheonix, Arizona. 

We're a quarter of the way into this century, and a lot has happened. When we think about today's connected factories, in many cases controlled by tablets and smartphones, we should remember that virtually none of that was possible as recently as the turn of the century. Throughout the past few weeks, editors at IndustryWeek have been publishing game changers stories, a look into the 25 events that have reshaped the manufacturing landscape. From terrorist attacks on Sept. 11, 2001, to the 2008 economic collapse to COVID-19, it's been an eventful century so far. In this podcast, our editors talk about what they learned from the giant look back -- which game changing events took them by surprise and which ones did they enjoy learning more about?

In this episode of Great Question: A Manufacturing Podcast, New Equipment Digest's Editor-in-Chief, Laura Davis, explores the differences between wireless bridges and access points, and why most facilities will need both to keep operations running smoothly. Listeners will learn how each technology works, when to deploy them, and the real-world benefits they deliver across industries from logistics to oil & gas. This episode is based on an article originally written by Henry Martel, a field applications engineer at Antaira Technologies.

Joe Kuhn, CMRP, former plant manager, engineer, and global reliability consultant, is now president of Lean Driven Reliability LLC. He is the author of the book “Zero to Hero: How to Jumpstart Your Reliability Journey Given Today's Business Challenges” and the creator of the Joe Kuhn YouTube Channel, which offers content on starting your reliability journey and achieving financial independence. In our monthly podcast miniseries, Ask a Plant Manager, Joe considers a commonplace scenario facing the industry and offers his advice, as well as actions that you can take to get on track tomorrow. In this episode, Joe discusses the importance of planned work coordination.

In this episode of Great Question: A Manufacturing Podcast, Robert Brooks speaks with Denny Williams of Co-Line Manufacturing and Doug Wood of Hexagon Production Software about the intersection of workforce development and technology in manufacturing. The conversation explores how Co-Line fosters a strong culture to attract and retain talent, the role of apprenticeships in bridging the skills gap, and the ways automation and robotics are being integrated to complement—not replace—workers. They also discuss how software, connected workflows, and emerging AI applications are shaping the future of efficiency and competitiveness in the industry.

Dave Blanchard, chief editor of Material Handling & Logistics and author of Supply Chain Management Best Practices, looks at how AI and other technologies are helping companies get smarter and more competitive with their supply chains. Learn what types of AI solutions retail giant Walmart is using to determine exactly what products its customers will want, and when they'll want them. You'll also find out why supply chain professionals need to get smarter at articulating the ROI of supply chain solutions.

We love our human-shaped robots in pop culture. From Lieutenant Commander Data to C3P0 to Baymax. But, are they any good at making things? At the Automate show this year, humanoid robots peppered the show floor, lifting boxes, walking around, picking up tools... slowly. Very, very slowly. For all of the promise of lifelike robots that can replace human workers on the assembly line, one-for-one, they aren't meeting that promise yet. Last year, Tesla caught flak for using human pilots to remote-control Optimus robots during a launch event.  Ujjwal Kumar, group president of Teradyne Robotics, says automated humanoids are cool, but they're not terribly practical. Why force a robot to stand on two legs when wheels could get them across a shop floor faster and with greater stability? Why create a standalone, human-like machine that needs batters when you could install an arm with a power source? In this formerly live conversation, we discuss why humans are so much better at some tasks and why a humanoid robot isn't a great solution. 

In this episode we'll discuss next-generation manufacturing use cases, implications around increased OT digitization, and the networking capabilities required to future-proof operations. This episode is sponsored by Cisco. 

In this episode of Great Question: A Manufacturing Podcast, Thomas Wilk is joined by Chris van den Belt and Berend Booms of Ultimo, an IFS company, for a conversation on the rise of agentic AI in enterprise asset management. The discussion explores how AI is moving beyond traditional copilots to become autonomous digital coworkers that enhance safety, streamline maintenance, and support frontline workers in dynamic environments. Together, they highlight real-world use cases, from improving incident reporting to optimizing preventive maintenance and inventory management.

Fastenal's Ryan Tucker and Sara Weaver share how the company has transformed and grown their workplace safety program over the past 12 years and what they're focusing on next. A preview of Safety Leadership Conference 2025, held Oct. 20-22 in Phoenix: www.safetyleadershipconference.com

There's more than a little bit of Tesla talk in Ford's announcement on Aug. 11, that it would invest $2 billion to retrofit its Louisville Assembly Plant to make a small electric pickup in 2027. It's a bold, ambitious plan that's equal parts going after Chinese competition, heating up leftover Tesla ideas and taking advantage of the scale of a massive global automaker.  Pieces of the plan touch on multiple aspects of the manufacturing industry that we care about at Endeavor B2B's Manufacturing Group -- safety/ergonomics, manufacturing procedures, casting technologies and what the vehicle factory of the future might look like. IndustryWeek Editor-in-Chief Robert Schoenberger, who spent four years earlier in his career writing about the Ford plant for The Courier-Journal in Louisville, discusses Ford's plans, where it's fudging the numbers a bit and how it hopes to create a new manufacturing paradigm in Kentucky, with a little help from Ford executives and engineers who spoke at the investment announcement.

When a forged part is labeled “capable of ASTM A388,” what does that really mean? And more importantly, what does it not mean? In this episode, we break down the difference between a part that could theoretically pass ultrasonic testing and one that's actually been tested. We'll look at why that difference matters in industries where safety and reliability are critical, explore common internal defects in forgings, and explain why proper surface preparation is key to accurate ultrasonic inspection. If you'd like to dive deeper into the details, you can read the full article here: https://www.newequipment.com/55279288

Joe Kuhn, CMRP, former plant manager, engineer, and global reliability consultant, is now president of Lean Driven Reliability LLC. He is the author of the book “Zero to Hero: How to Jumpstart Your Reliability Journey Given Today's Business Challenges” and the creator of the Joe Kuhn YouTube Channel, which offers content on starting your reliability journey and achieving financial independence. In our monthly podcast miniseries, Ask a Plant Manager, Joe considers a commonplace scenario facing the industry and offers his advice, as well as actions that you can take to get on track tomorrow. In this episode, Joe shares his leadership experience on turning maintenance mistakes into learning experiences.

In this episode of Great Question: A Manufacturing Podcast, Robert Brooks explores three key developments in non-ferrous metallurgy that promise to reshape industrial manufacturing. The discussion highlights breakthrough research from the Pacific Northwest and Ames National Laboratories, including advances in solid-phase alloying of aluminum scrap and the discovery of a new multi-element alloy for high-temperature turbine applications. Robert also examines Arconic's collaboration with spectroscopy experts to enhance real-time analysis of molten metals. Together, these innovations point to a future where metallurgical progress drives both performance and sustainability across sectors.

Rocky Rowlett, vice president of safety, and Alyssa Kwasny, wellness program director, explain how their energy and construction firm, Faith Technologies Inc., has become an exemplar of world-class safety excellence by developing a culture of care.

The problem sounds so simple: Manufacturers need large numbers of new employees to replace retiring Baby Boomers. Lots of Millennial and Gen Z young people want good jobs One reason why the sides aren't connecting, workforce watchers say, is that young people are often unaware of the opportunities being offered in factories and job shops nationwide. At least one plant is addressing that.  International Motors' commercial truck plant in San Antonio, Texas, has been working with greater:SATX, the city's economic development organizations, to encourage high school students to intern and the recently opened manufacturing facility. Several of those recent high school grads have since taken full-time positions at International.  Hear more about the program from students-turned employees, International's leadership team and from the people who are training and worth with those young people.

Industry 4.0 is still a vague term to many in manufacturing. To some, it's projects that fit the strict standards of the German consortium that developed the term. For others, it's synonymous with Industrial Internet of Things connectivity – systems that draw data from machines to optimize processes. Most agree, however, that it's a tech thing. Industry 4.0 advocates talk about the need to manage workers differently, but the thrust of the movement is machine learning, data collection, data-based decision modeling and data-driven process improvement. So, where do people have a say? To Sarah Tilkens, a former GE Healthcare lean guru who now runs the KPI Lab, that's why we need Industry 5.0. “The problem (with Industry 4.0) is with the focus so much on productivity and efficiency. People became really, really burned out and disengaged,” Tilkens said. “So, a lot of the systems became very rigid. They weren't as flexible. They weren't as creative. And I think that's what led to… Industry 5.0, which again is all around human led innovation.” Tilkens shared her thoughts with IndustryWeek editor Jill Jusko, someone who's spent 25 years writing about continuous improvement and operational excellence.

In this episode of Great Question: A Manufacturing Podcast, Thomas Wilk, chief editor of Plant Services, sits down for a roundtable discussion with: Chris Hallum, UE Systems operations manager for North Europe Chad Coleman, Amazon senior reliability engineer Pat Caron, Amazon reliability engineering manager Jeremy Bey, UE Systems strategic accounts leader.  The discussion explores the evolution from isolated maintenance efforts to a unified, data-driven strategy that emphasizes standardization, training, and cross-regional collaboration. This episode offers practical insights for anyone navigating the complexities of reliability at scale.

Joining Smart Industry's Scott Achelpohl for this episode is Rajeev Shah, co-founder and CEO of Celona, who helps explain how manufacturers can overcome “legacy” infrastructure challenges—particularly their older OT—to harness the potential of AI-driven operations.

In this episode of Great Question: A Manufacturing Podcast, Rosemary Coates, executive director of the Reshoring Institute, shares insights on how companies are navigating the changing business environment and reshoring trends in 2025.

In this “in case you missed it” podcast, you'll learn why Travis S. McConnell, a construction attorney with Ready Legal, believes that implementing a comprehensive safety program is essential to preventing injuries and complying with OSHA's standards.  You can also read the full article here.

Armstrong World Industries set a goal, nearly a decade ago, to be an outlier, the kind of company that maintains 5% profit growth for five or more years. Those efforts have paid off with the ceiling-tile and architectural components making landing No. 2 in IndustryWeek's annual IW U.S. 50 Best Manufacturers list. Vic Grizzle, CEO of Armstrong, sat down with IndustryWeek's Robert Schoenberger to discuss the management philosophy behind that performance. Some key elements: Investing in the business: Armstrong dedicates more of its cashflow to operational improvements than many of its peers, part of an annual push to increase productivity by about 3% every year Championing stability: Customers and employees know what to expect from a company that has stable management and rarely changes big-picture strategies Adaptability: While it champions stability, Armstrong also looks for adjacent opportunities, experiments with new technologies and constantly updates its processes

In this episode of Great Question: A Manufacturing Podcast, Thomas Wilk, chief editor of Plant Services, is joined by Blair Fraser, the VP of technology at UE Systems to discuss how ultrasound tools are evolving. Many maintenance technicians use machine condition monitoring technologies for two related goals: detect a problem, and diagnose the root cause. However, Fraser argues that these technologies are evolving quickly to help teams achieve the next-step goal of deciding on the best corrective course of action that fits overall plant goals.

David Brown, vice president and CTO of Transportation Solutions at TE Connectivity, shares how AI is driving faster product design, smarter factories, and a better-trained workforce. From generative design to predictive maintenance, learn how TE's AI strategy keeps them ahead in a rapidly evolving industry. Visit te.com for more information. Read TE's 2025 Industrial Technology Index here.

Joe Kuhn, CMRP, former plant manager, engineer, and global reliability consultant, is now president of Lean Driven Reliability LLC. He is the author of the book “Zero to Hero: How to Jumpstart Your Reliability Journey Given Today's Business Challenges” and the creator of the Joe Kuhn YouTube Channel, which offers content on starting your reliability journey and achieving financial independence. In our monthly podcast miniseries, Ask a Plant Manager, Joe considers a commonplace scenario facing the industry and offers his advice, as well as actions that you can take to get on track tomorrow. This episode explains some of the problems that can go wrong when you are starting your reliability journey, and what folks should be on the lookout for along the way. Key takeaways Prioritize reliability by choosing where to excel—get a C on less critical tasks to focus on what truly drives plant performance. Reliability success demands active operations ownership—learn failures, engage on the floor, and earn credibility. Promote small wins visibly—selling reliability outcomes prevents loss of sponsorship and ensures long-term buy-in. Without structured problem-solving, best practices fall short—embed it into your process to triple reliability results.

In this episode, American Machinist editor in chief Robert Brooks analyzes the current state of the additive manufacturing (AM) sector, after several years of organizational turmoil among the top suppliers of AM systems. Brooks argues that this turmoil had virtually nothing to do with AM processes or technology developments, arguing that investors have been impatient with the rate of worldwide AM adoption. 

Chris Williams, executive director of the Voluntary Protection Programs Participants' Association (VPPPA), offers a preview of the upcoming Safety+ Symposium, to be held August 11-14 in St. Louis. This annual event provides attendees with the opportunity to see safety from all angles and better understand its role in the modern workplace. EHS Today's Safety Leadership Conference is an official media sponsor of this event.

In this sponsored episode of Great Question: A Manufacturing Podcast, Thomas Wilk, chief editor of Plant Services, is joined by Maureen Gribble, North American sales enablement leader for UE Systems, and John Gould, director for global business development for condition monitoring at Flir. Ultrasound and infrared thermography tools are increasingly used together by maintenance teams that want to get a fuller picture of asset health. In this podcast episode, sponsored by UE Systems, Tom talks with Maureen and John about the ways these tools are being used in the field, including hybrid tools like acoustic imagers, as well as what the future hold for the partnership between Flir and UE Systems.

Fluid sealing is critical to the safe, reliable, and efficient operation of industrial equipment across industries like oil and gas, petrochemical, power generation, and manufacturing. In this podcast, we'll explore how fluid sealing practices have evolved to meet modern demands for environmental compliance, equipment longevity, and cost-effectiveness. We'll discuss the latest material advancements, emission-reduction technologies, and digital monitoring tools that are reshaping the landscape. Listeners will gain insights into how companies are balancing traditional reliability practices with the push for sustainable solutions, such as low-emission mechanical seals, advanced gaskets, and innovative air seal designs. We'll also touch on common challenges end users face today — from supply chain constraints to skills gaps — and how industry leaders are adapting their approaches. Whether you're an engineer, maintenance manager, or reliability professional, this episode offers a practical look at the future of fluid sealing.

Cam Mackey, president & CEO of the International Safety Equipment Association (ISEA), explains why every heat-related death in the workplace is preventable, and offers some tips on how to best protect workers from heat stress.    https://www.osha.gov/emergency-preparedness/guides/heat-stress

The Eastern half of the United States is experiencing record high temperatures. It's summer and all, so some heat is to be expected, but that doesn't make it any easier for the workers in factories or the people trying to maintain the national power grid. Discussing worker safety and power availability in the hot summer are: Dave Blanchard, editor-in-chief of EHS Today Robert Schoenberger, editor-in-chief of IndustryWeek Jeff Postelwait, managing editor of T&D World We discussed how to spot signs of heat stress and how the nation's obsession with ChatGPT may lead to blackouts.

The company's chief engineer and transformation leader Bradly Walker joins Smart Industry's Scott Achelpohl and IndustryWeek's Dennis Scimeca to chat about Texas Pride's technology renaissance and how it's helped the manufacturer evolve its sales, warranty, and production processes from legacy Excel spreadsheets and paper-based systems.

In this episode of Great Question: A Manufacturing Podcast, Thomas Wilk, chief editor of Plant Services, is joined by Brian Hronchek, principal trainer and consultant with Eruditio, to discuss a topic in the air these days: PM optimization. These efforts start with the question, “What is the outcome that you want?” And that outcome is for the seasoned technician and the new technician to be able to return exactly the same results when they do the same inspection on a mechanical asset. Key takeaways PM optimization starts with clear goals: inspections should yield identical results from both seasoned and new technicians. Many PMs lack value—use metrics like PM/PdM yield to identify and improve or eliminate ineffective tasks. Aligning maintenance with planning and scheduling reduces downtime and prevents reactive repair chaos. Trimming bloated PMs and focusing on useful inspections can boost uptime, cut stress, and streamline production.

John Dony, CEO and co-founder of What Works Institute, explains why policies, procedures and other accommodations for neurodivergent workers can make work safer for everyone. 

Large language model (LLM) AIs have captured the world's attention with their ability to interpret plain-language and convert simple queries into machine language. But, the big advances in manufacturing design and execution are going to rely on updated hardware, says Deb Golden, chief innovation officer at Deloitte.  At Siemens recent Realize Live event in Detroit, Golden sat down with IndustryWeek Editor-in-Chief Robert Schoenberger to talk about where companies can leverage manufacturing technologies to gain an edge. And at just about every turn, the conversation returned to hardware.  AI is giving companies a better view of their operations? “We're in such a rush to make humans think better, faster, quicker. The only way we could do that is with compute time and space,” Golden said. “We have to know the health of the actual hardware that [manufacturing processes are] operating on. I don't care where that [compute] hardware is, if it's sitting on prem, if it's sitting in the cloud, if it's sitting literally in outer space on the satellite.”

Joe Kuhn, CMRP, former plant manager, engineer, and global reliability consultant, is now president of Lean Driven Reliability LLC. He is the author of the book “Zero to Hero: How to Jumpstart Your Reliability Journey Given Today's Business Challenges” and the creator of the Joe Kuhn YouTube Channel, which offers content on starting your reliability journey and achieving financial independence. In our monthly podcast miniseries, Ask a Plant Manager, Joe considers a commonplace scenario facing the industry and offers his advice, as well as actions that you can take to get on track tomorrow. This episode explains why running time-based and condition-based maintenance in parallel is a costly mistake. Key takeaways Condition monitoring won't be perfect at first—expect a learning curve and commit for long-term gains. Avoid running time-based and condition-based maintenance systems together—it wastes resources. Pair condition monitoring with root cause analysis to drive real business impact. Protect condition monitoring resources from daily disruptions—require plant manager approval to reassign.

In this episode, listeners will gain insights into how air seal technology is revolutionizing the plastics film industry to reduce waste, save money, and promote more sustainable manufacturing processes. Addressing things like: Environmental and sustainability concerns, waste and housekeeping improvements and enhanced plant safety initiatives.

Electricity demand is soaring around the world, and in the U.S. electric supply is dwindling. Manufacturers may not have realized this – but they will, and very soon, as electric utilities begin to apply capacity charges to their supply costs. In this installment of the Great Question podcast, energy consultant Brian Reinke – author of a new article – diagnoses the problem and suggests how manufacturers might prepare themselves to address the surging electricity costs. 

Mental Health First Aid (MHFA) at Work for Manufacturing, launched by the National Council for Mental Wellbeing, is a series of four courses designed to improve mental health literacy among employees and leaders in the manufacturing industry. Lynn Burke Hennighausen and Rob Vallentine, national trainers for the program, joined IndustryWeek during Mental Health Awareness Month to discuss mental health challenges in manufacturing and how the MHFA training program can lead to a safer and more productive work environment.