Smart Metals Podcast

Ensuring Data Quality in Metals Manufacturing: Techniques and Challenges with SCADA and Databricks

In this episode of the Smart Metals Podcast, hosts Luke van Enkhuizen and Denis Gontcharov explore the critical topic of data quality in metals manufacturing, with a strong focus on SCADA systems and modern cloud platforms like Databricks.  Denis kicks off with a big announcement: his business is now refocused on integrating legacy SCADA architectures with scalable cloud-native environments such as Azure Databricks. Together, Luke and Denis dive into the key challenges of aligning SCADA data with business use cases, the erosion of trust caused by bad data, and the urgent need for automated monitoring.  The discussion emphasizes how companies—from SMBs to enterprises—can implement robust data quality testing using open-source frameworks like Soda and Great Expectations. You’ll learn how to embed testing into ETL pipelines, use Databricks to store and analyze data reliably, and ensure high-quality inputs within a Unified Namespace (UNS).   Timestamps:  00:00 Introduction to the Smart Metals Podcast  00:44 Big Announcement: Refocusing Business Activities  01:12 Understanding SCADA and Data Quality Challenges  04:37 Importance of Data Quality in Manufacturing  07:22 Real-World Data Quality Issues and Consequences  11:04 Steps to Ensure High Data Quality  27:00 Open Source Solutions for Data Quality Testing   Notable Quotes:  1. “SCADA is essentially the second layer of the automation pyramid—supervisory control and data acquisition. It collects data from PLCs and individual machines. The challenge is moving this high-frequency, millisecond-level time series data to the cloud. Data quality is one of the key problems in this area.” – Denis Gontcharov 2. “My new focus is helping companies integrate legacy SCADA systems into modern platforms like Azure Databricks, where they can finally get control over their industrial data.” – Denis Gontcharov 3. “Almost any factory using modern machinery has multiple layers—sensors, PLCs, SCADA, MES, ERP, and eventually the cloud. Much of this may be hidden inside vendor-specific solutions, but understanding these layers is essential.” – Luke van Enkhuizen 4. “Bad data completely erodes trust. If your dashboard shows an off number and you can’t explain it, users stop trusting your data platform—no matter if it’s SCADA or Databricks behind the scenes.” – Denis Gontcharov 5. “You can’t manually verify data coming from hundreds of time series across SCADA systems. You need an automated application watching your data 24/7 and flagging anomalies before they affect operations.” – Denis Gontcharov 6. “Where should you do data quality checks? Ideally, inside your pipeline—after transformations—whether you’re using SCADA historians or sending data into Databricks. This prevents dirty data from entering your clean system.” – Denis Gontcharov 7. “ETL stands for extract, transform, load. As you bring SCADA data into Databricks or your UNS, every step must be monitored and tested.” – Denis Gontcharov 8. “Just like raw ore needs refining before it becomes usable gold, raw SCADA data must be cleaned, structured, and tested—often inside platforms like Databricks—to unlock its real business value.” – Luke van Enkhuizen   Relevant Links:  * 🔗 Follow the show: https://smartmetals.transistor.fm/ [https://smartmetals.transistor.fm/] * 🔗 About Denis Gontcharov: https://gontcharov.eu/ [https://gontcharov.eu/] * 🔗 About Luke van Enkhuizen: https://vanenkhuizen.com/ [https://vanenkhuizen.com/]

Unified Namespace Deployment in Metal Fabrication: A Real-World Case Study

In this episode of the Smart Metals Podcast, Luke van Enkhuizen and Denis Goncharov dive into a real-world case study of deploying a Unified Namespace (UNS) at a welding shop in the Netherlands using the United Manufacturing Hub (UMH).  They discuss the challenges of integrating ERP and MES systems, why traditional point-to-point connections often fail, and how a UNS enables real-time visibility, data flexibility, and scalability.  🔹 What you’ll learn in this episode: ✅ Why a UNS was chosen over traditional integrations ✅ How the system was deployed in just one day ✅ The business benefits: real-time alerts, scalability & low cost ✅ How SMBs can leverage enterprise-grade software without major investment  🎧 Listen now and learn how to future-proof your digital transformation!   Timestamps:  00:00 – 🎙️ Welcome to the Smart Metals Podcast  00:50 – 🔍 Understanding the Client’s Needs  02:07 – 🏭 Why Choose a Unified Namespace?  05:43 – ⚙️ Implementing the United Manufacturing Hub  11:35 – 🔄 Deployment and Real-Time Success  20:47 – 🚧 Challenges and Lessons Learned  27:19 – 🌍 Future Prospects and Final Thoughts   Notable Quotes:  📢 "Why not just make a point-to-point connection between the ERP and the MES system? The answer lies in real-time visibility. We needed flexibility to change things over time, and the MES system was a closed, off-the-shelf solution. A Unified Namespace gave us the control we needed to integrate multiple systems seamlessly." – Luke van Enkhuizen  📢 "One of the key reasons we chose a Unified Namespace was future expandability. Today, we’re integrating ERP and MES, but tomorrow we may need to add SCADA systems, cloud data, or even CRM insights. With a UNS, we build an independent system that grows with the business." – Denis Goncharov  📢 "The biggest frustration with traditional point-to-point integrations is that they break. Data gets out of sync, connections fail, and you end up manually fixing errors. A UNS ensures that everything stays aligned in real-time without those fragile dependencies." – Luke van Enkhuizen  📢 "We managed to develop and deploy the entire solution in just one day. By following IT best practices and leveraging the United Manufacturing Hub, we had everything prepared before even stepping onto the factory floor. That level of efficiency is a game-changer." – Denis Goncharov  📢 "You don’t need to start with the perfect business case—just a direction. Once we implemented the UNS, the client immediately saw 10 more opportunities they could tackle. That’s the real power of having an open, scalable data infrastructure." – Luke van Enkhuizen   Links & Resources:  🔗 Follow the show: https://smartmetals.transistor.fm/ [https://smartmetals.transistor.fm/] 🔗 About Denis Goncharov: https://gontcharov.eu/ [https://gontcharov.eu/] 🔗 About Luke van Enkhuizen: https://vanenkhuizen.com/ [https://vanenkhuizen.com/]   Support the Podcast!  ✅ Sharing is Caring! If you liked this episode, please consider sharing it with colleagues who might find it useful. 😊 ✅ Rate the Show! Did this episode give you new ideas? Leave us a 5-star review on iTunes or Spotify to help more people discover the podcast! ⭐⭐⭐⭐⭐   Ready to Listen?  🎧 Press play and discover how a Unified Namespace can transform your factory floor! 🚀

From the Shop Floor to the Cloud: AI in Metal Manufacturing

In this episode of the Smart Metals Podcast Denis and I, dive into the topic of transferring shop floor data to the cloud and leveraging AI for predictive maintenance and other use-cases in the metals industry.  We discuss essential components like the Unified Namespace (UNS) and Data-Centric AI, highlighting why smaller manufacturers shouldn’t shy away from cloud technology. We also break down common misconceptions about AI, particularly for SMBs, and explore the benefits of cloud services.  You’ll hear a step-by-step approach to implementing predictive maintenance and get practical advice on how to start using AI-driven insights—without excessive costs or complexity. If you're a manufacturer looking to make data-driven decisions, optimize maintenance strategies, and leverage AI in a practical, actionable way, this episode is a must-listen. Topics 00:00 – 🎙️ Welcome to the Smart Metals Podcast 00:23 – 🔍 Understanding Shop Floor Data and AI 02:29 – ⚙️ Preventive vs Predictive Maintenance 04:57 – 🔄 Steps to Implement Predictive Maintenance 08:10 – ☁️ Benefits of Cloud Solutions 09:46 – 📊 Data Management and Unified Namespace 28:57 – 🏭 Practical Advice for Manufacturers Notable Quotes: 1. "We always break it down into having a solid data infrastructure and having a solid data strategy. And both of these concepts can be summarized with two words respectively: the Unified Namespace and Data-Centric AI." – Denis Gontcharov 2. "Very often, we talk about AI and especially cloud, and smaller manufacturers think, ‘Oh, that’s something for enterprises.’ The goal today is to dispel this myth and tell you that the cloud is far more accessible than you may imagine." – Denis Gontcharov 3. "Preventive maintenance is like going to the gym and eating healthy to avoid getting sick, while predictive maintenance is like wearing a smartwatch that warns you when you’re about to have a health issue." – Luke van Enkhuizen 4. "If we’re just copying our existing systems to the cloud, why would anyone use them there instead of on-premises? We have to provide them with something better—something with more context, better-organized data, and real insights." – Denis Gontcharov 5. "The cloud is not just a place to store data; it’s a new way of organizing infrastructure. If we’re just renting a big computer in the cloud and copying all our applications, we’re not using the cloud in the right way." – Denis Gontcharov 6. "Manufacturers shouldn’t fear the cloud—it’s not just for enterprises. Because of its pay-as-you-go structure, it’s surprisingly affordable and far more flexible than building your own data center." – Denis Gontcharov 7. "AI equals model plus data. The old way focused on tweaking the model, but today, improving the data itself—what we call Data-Centric AI—often leads to better results." – Denis Gontcharov 8. "If someone comes to your factory and says, ‘We have the perfect solution for you, and it costs six digits,’ you should probably walk the other way." – Luke van Enkhuizen Relevant Links: 🔗 Follow the show: https://smartmetals.transistor.fm/ [https://smartmetals.transistor.fm/] 🔗 About Denis Gontcharov: https://gontcharov.eu/ [https://gontcharov.eu/] 🔗 About Luke van Enkhuizen: https://vanenkhuizen.com/ [https://vanenkhuizen.com/] Sharing is caring! If you liked this episode, please consider sharing it with some friends or colleagues who might find it useful. Thank you! 😊 Would you like to help? Did this show help you with new ideas for your business? Then rate the show on iTunes or Spotify. This helps people like you find the show and us to be able to book more guests with industry specialists and top solution providers. ⭐⭐⭐⭐⭐

Navigating the Future of Factory Connectivity with Russ Waddell

This week at Smart Metals Podcast, we, the hosts Denis Gontcharov and Luke van Enkhuizen, had a fascinating conversation about the future of factory connectivity with Russ Waddell, an expert in industrial connectivity. We explored the challenges of integrating manufacturing systems, the importance of cultural and technological shifts, and how to leverage AI and data science to unlock the full potential of manufacturing processes. We delved deeper into topics like the evolution of industrial connectivity, unified namespaces, and strategies for starting your digital transformation journey. If your current challenge is connecting your manufacturing systems, scaling digital projects, or understanding how to use your data effectively, then listen to this episode when you have a moment. 🎧 LISTEN NOW ➡️ Topics [00:00] 🎙️ Welcome to the Smart Metals Podcast [00:40] 🔍 Russ Waddell: Journey into Industrial Connectivity [08:20] 🌐 Defining Factory Connectivity [17:44] 🚧 Challenges and Opportunities in Factory Connectivity [27:52] 🏭 Evolution of Machining and Paperless Operations [29:18] 💡 Technological Advancements and Their Impact [32:13] 🛠️ The Role of Software in Modern Manufacturing [36:21] 🔮 Future Trends and Cultural Shifts in Manufacturing Interesting Quotes • “If you could just see the data in all of your industrial controllers… Imagine what you could do with that. Everything else we talk about comes back to your favorite use case for that data.” – Russ Waddell • “When we talk about factory connectivity, everyone has a different definition. A machine maker, a software seller, or someone on the factory floor will all see it differently. That’s why it’s so important to have conversations like this to get a clearer picture.” – Luke van Enkhuizen • “AI has created a major use case for having all the data in one place. That’s why connectivity is more relevant than ever.” – Denis Gontcharov • “AI is clearly the next step after basic monitoring and predictive analytics. But it needs clean, accessible inputs. The cleaner the data, the more time your team can spend on building algorithms instead of copying and pasting from CSV files.” – Russ Waddell • “When you step into some manufacturing facilities, it feels like you’re back in the 80s or 90s. That’s not just a technology problem—it’s a cultural one. Companies need to learn what’s possible and build small-scale successes to see the potential.” – Luke van Enkhuizen

Unifying Manufacturing with Unified Namespace: A Conversation with Brian Pribe

This week at Smart Metals Podcast, we, the hosts Denis Gontcharov and Luke van Enkhuizen, had a conversation about implementing Unified Namespace (UNS) in manufacturing environments with Brian Pribe, founder and president of MACH Controls LLC. We explored how to make advanced manufacturing technology accessible to businesses of all sizes.  We delved deeper into practical implementation of UNS, the combination of MQTT and Kafka, and making these solutions affordable for smaller manufacturers. If your current challenge is connecting your manufacturing equipment or implementing a unified namespace solution, then listen to this episode when you have a moment.  Topics  * [00:00] Introduction to the Smart Metals Podcast * [00:32] 📊 Brian Pribe's Journey in Manufacturing and MACH Controls LLC * [01:59] 🚀 Understanding and Implementing Unified Namespace * [04:45] 🌐 Technical Deep Dive: MQTT and Kafka Integration * [11:14] 📋 European Data Act and Its Impact on Manufacturing * [16:13] 💡 Making Technology Accessible for Small Manufacturers * [23:03] 📈 Unlocking Business Insights with Unified Namespace * [24:52] 🏭 First Steps: From Strategy to Proof of Concept * [28:35] 🔄 Integrating IT and OT Systems * [31:32] 🔮 Future of Manufacturing and Generational Transition Interesting Quotes * "The Unified Namespace isn't just about connecting devices - it's about contextualizing data in a way that makes sense for your business." – Brian Pribe * "For non-critical applications, open source all the way. Start with FOSS solutions. It's not going to cost you anything, and it's going to push you in the right direction." – Brian Pribe * "You can only improve what you measure. And if you're not measuring anything, you're not going to improve at all." – Brian Pribe * "I think the biggest challenge is not per se that the machines don't have the connectivities. It's the fact that most users of the machines are not even remotely aware how many sensors and computer systems are actually in their plant." – Luke van Enkhuizen * "The licensing costs for connecting machines through OPC UA can be substantial - manufacturers end up spending significant amounts yearly just to get data." – Denis Gontcharov * "Something has to give - your profit margins are really not that outstanding. Why not just get the data and measure what you want to improve? Otherwise you won't." – Denis Gontcharov Resources: * 🔗 Follow the show: Smart Metals Podcast [https://smartmetals.transistor.fm/] * 🔗 About Denis Gontcharov: gontcharov.eu [https://gontcharov.eu/] * 🔗 About Luke van Enkhuizen: Sheet Metal Connect [https://sheetmetalconnect.com] * 🔗 About Brian Pribe: LinkedIn Profile [https://linkedin.com/in/brianpribe] * 🔗 MACH Controls LLC: machcontrols.com [https://www.machcontrols.com] * 🔗 Email Brian: bpribe@machcontrols.com [bpribe@machcontrols.com] * 🔗 Join the Community: Find Brian on United Manufacturing Hub's discord or 4.0 Solutions discord Sharing is caring! If you liked this episode, please consider sharing it with some friends or colleagues who might find it useful. Thank you! 😊 Would you like to help? Did this show help you with new ideas for your business? Then rate the show on iTunes or Spotify. This helps people like you find the show and us to be able to book more guests with industry specialists and top solution providers. ⭐⭐⭐⭐⭐