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

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

• (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

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If you like this podcast, get more episodes at controleng.com or ctrlaltmfg.castos.com.

• (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.

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If you like this podcast, get more episodes at controleng.com or ctrlaltmfg.castos.com.

• (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