275: Building a Brand New Manufacturing Company in the US with Andrew Johnson, Co-Founder of HeavyTech

Manufacturing has been collecting skills for centuries, and the list keeps growing. Chris takes Manufacturing Happy Hour to Revere Electric’s Executive Forum at the University of Wisconsin-Milwaukee (UWM) for a live conversation about what the factory of the future needs in the plant and in the workforce. Joining him are Michael Cvelbar and Phil Bush of Rockwell Automation, Joe Hamann of the Connected Systems Institute (CSI), and Ryan Schneeberger of Revere Electric Supply. Joe and Phil look at how new people get job-ready through student hackathons and a veteran training program. Ryan and Michael cover the other side, keeping people on the floor and giving operators more to do once they’re there. Students learn where AI adds value, while manufacturers want to see the return before they invest. And a room full of manufacturers toasts every time they say “digital twin.” In this episode, find out: Why Michael says manufacturers need backup plans when disruption hits How Rockwell is preparing operators to troubleshoot their own equipment Why manufacturers say new engineering graduates can take years to reach full productivity How Rockwell’s Academy of Advanced Manufacturing trains military veterans as controls technicians What flexible automation can do for a customer and why manufacturers stay cautious on AI until the ROI is clear How Phil, Joe, Ryan and Michael describe their factory of the future when the audience asks

Manufacturing has a lot to gain from AI, and a lot to lose by waiting. Recorded at mHUB in Chicago’s West Loop during IMTS (International Manufacturing Technology Show), Chris sits down with Sanjay Brahmawar, CEO of QAD Redzone, to talk about what AI could mean for an industry facing 500,000 open manufacturing jobs and a growing need to do more with the people it already has. They also look at what happens when systems of record become systems of action, and how that changes the way manufacturers respond to problems on the shop floor. In this episode, find out: How a career that started on a Honda engine line shaped Sanjay's view of manufacturing as managing constraints Why manufacturers don't need to replace their existing technology before putting AI to work How AI can turn a system of record into a system of action on the factory floor What QAD Redzone learned after giving line leads an AI agent before bringing their supervisors into the conversation Why some manufacturers are willing to set aside 5-7% of their IT budget for AI How a month of 24/7 bug fixing, complete with its own t-shirts, helped QAD Redzone rebuild customer trust

RVs are homes that go 60 miles an hour. That changes everything about what goes inside them. Chris sits down with Sean Petterson, CEO of Supersede, a company combining recycling and manufacturing in an unexpected way - turning recycled plastic into structural building materials. Supersede started with boats, where wood has an obvious problem - boats get wet! From there, the company moved into RVs, where the materials face constant movement and thermal cycling, on a production line that can build an entire RV in a couple of hours. Sean also explains the thinking behind Supersede's manufacturing model, including why he'd rather build 10 smaller plants than one big one. In this episode, find out: How running production lines in mirrored pairs cuts the distance operators walk across the floor Why an RV, built to go 60 miles an hour, is a harder test for a material than a house that never moves How Supersede built its own ERP with zero software developers, piecing it together through Slack, Jira, and GitHub instead How a pre-sold capacity threshold - already dropping fast - decides when Supersede builds its next plant How embedding machine vision and LiDAR on the line replaces a QA machine that would otherwise cost far more Why Sean thinks manufacturers who didn't start using AI a year ago are already a decade behind

There's a lot more coming out of Iowa than corn. Chris heads to Des Moines for a live conversation with four guests who each know Iowa manufacturing a little differently. Dominique Hain and Cami Schaefer share how Women in Manufacturing Iowa grew to over 900 members in three years. Denny Williams and Denise Hill take it from there, discussing automation, hiring, and just how deep Iowa's farm roots run through its factories. The conversation also uncovers some of the products many people may not know are made in Iowa, including Winnebago RVs. In this episode, find out: What makes a state better known for agriculture become one of the country's stronger manufacturing bases How Iowa's farming communities are shaping who gets hired at companies like Weiler Which surprising products are actually made in Iowa, from butter braids to basketball hoops Why so many Iowa manufacturers trace back to a farmer solving a problem for himself, then his neighbors How Co-Line is using robots and cobots to boost throughput without cutting its workforce Why finding qualified operators is harder than finding corn in rural Iowa

You can count on Philly to bring the energy! Recorded live in King of Prussia at the final stop of the Northeast leg of the All-American Manufacturing Summer Tour, this episode features the loudest, most engaged crowd Chris has had on the show yet. Ashley, Brett, and Matt open the show with a look at what makes the Philadelphia manufacturing ecosystem tick, and why collaboration, not competition, might be the region's biggest advantage. Hannah and Greg then join Matt to talk workforce development, and some of the most creative approaches to the talent shortage you'll hear on the show all year. In this episode, find out: What inspired one shop owner to build a group where members share equipment, knowledge, and even trade secrets with people who'd traditionally be seen as competitors Why locating a machine shop in the heart of Philadelphia, despite the traffic, parking, and wage tax, turned out to be a competitive advantage How a youth basketball nonprofit ended up building a skilled trades program for teenagers who don't want to go to college Why the region's defense industry is driving serious demand for skilled manufacturing workers What convinced a group of manufacturing leaders that hiring from a more diverse talent pool is a genuine business advantage, not just the right thing to do What it really takes to change how an entire generation sees a career in the trades