Abelara Ascent

Abelara

Abelara Ascent - Long-form conversations about what it actually takes to modernize manufacturing. Abelara Ascent is where architecture meets execution. Interviews with the people building real systems. Panel discussions that go deeper than the keynote. And solo episodes that break down the frameworks, decisions, and trade-offs behind industrial digital transformation. Hosted by Zack Scriven, Director of Sales and Marketing at Abelara, with regular appearances from cofounders Dylan DuFresne, Chief Architect, and Glenn Gardner, President. If you are a manufacturing leader, plant manager, controls engineer, or solutions architect trying to figure out where to start, what to prioritize, and who to trust, this is the show. Published by Abelara. Event coverage powered by Abelara Live.

Episodes

  1. 23 HR AGO

    CPG Manufacturing Masterclass: Fixing "Pilot Purgatory" with UNS & Data Foundation

    You have an MQTT broker. You have dashboards. You have data flowing from PLCs. And you still can't make any decisions. That is pilot purgatory. And it is more common than anyone in the industry wants to admit. In this episode, Ricardo Santos, Director at Tupinix, joins Zack Scriven and Dylan DuFresne to walk through what it actually takes to get value from a Unified Namespace in a CPG and food and beverage environment. Using Enterprise B, Capy Hour Inc., as the virtual factory for Abelara's ProveIt 2026 presentation, the team covers real use cases with real numbers. Chapters 00:00 — Welcome and Context 02:34 — Pilot Purgatory and Vendor Lock 04:58 — Ricardo's CPG Background 09:12 — When Digital Is Not the Answer Yet 19:57 — The Capy Hour Use Cases: Waste, OEE, Quality 26:14 — CIP Optimization with Data Visibility 31:47 — True OEE vs. Management OEE 41:36 — Why Raw Event Data Is the Foundation 43:57 — Utilities and Energy Management 51:00 — Tribal Knowledge and the Retiring Expert 58:16 — ProveIt 2026 and What to Expect Connect with Ricardo Santos: https://www.linkedin.com/in/ricardomarquessantos/ Connect with Dylan DuFresne: https://www.linkedin.com/in/dylan-dufresne-solutions/ Connect with Zack Scriven: https://www.linkedin.com/in/zackscriven/ Tupinix: https://tupinix.com/ Abelara: https://abelara.com Subscribe to Abelara Ascent: https://www.youtube.com/@AbelaraAscent #Abelara #AbelaraAscent #Industry40 #ManufacturingTransformation #DigitalTransformation #CPG #FoodAndBeverage #UnifiedNamespace #OEE #Bottling

    1hr 10min

  2. 27 APR

    Modern Manufacturing: The Full Stack with Dylan DuFresne, Travis Cox, Remus Pop & Craig Scott

    The podcast features a discussion among industry experts in manufacturing, focusing on the evolution of technology, the impact of Ignition, and the collaborative nature of the industry. The conversation delves into the challenges faced by end users, the importance of community, and the need for education and guidance in adopting new technologies. The conversation delves into the challenges and opportunities of enterprise-scale digital transformation, focusing on the concept of Unified Namespace (UNS) and its impact on manufacturing and industrial operations. The discussion emphasizes the importance of intentional deployment, data management, and the role of technology in driving value and transformation. The conversation covers the strategic relationship between Fuuz and Inductive, the role of data model-driven solutions, the importance of standards, the value of AI in factory connectivity, and the responsible use of AI and UNS. It also explores the impact of MQTT and Sparkplug in transforming architectures and the significance of leveraging AI and UNS for customers. Takeaways Industry 4.0 and digital transformationCommunity collaboration and open standards Enterprise-scale digital transformation requires intentional deployment and a focus on driving value through technology.The concept of Unified Namespace (UNS) plays a crucial role in creating interoperability and data management in industrial operations. Strategic relationship between Fuuz and InductiveRole of data model-driven solutionsImportance of standards and AI in factory connectivityResponsible use of AI and UNSImpact of MQTT and Sparkplug in transforming architectures Chapters 00:00 Introduction to the Full Stack of Manufacturing05:48 Legacy Pain Points and Modern Tools13:15 The New Paradigm in Manufacturing20:18 The Role of Fuuz in Enterprise Layer28:18 Challenges of Enterprise-Scale Deployment33:18 Unified Namespace (UNS) and Interoperability43:29 Success Stories and Adoption of UNS52:08 Mindset and Approach to Technology57:59 Value of AI and UNS for Customers01:15:14 Impact of MQTT and Sparkplug in Transforming Architectures

    1hr 19min

  3. 21 APR

    Data Modeling Across 5 Platforms: Ignition UDTs vs HighByte vs Litmus Edge vs Flow vs Fuuz

    Summary Dylan DuFresne and Zack Scriven go tool-by-tool through the five platforms that run most serious industrial stacks — Ignition, Flow Software, Litmus Edge, HighByte, and Fuuz — and answer the question every IT/OT team is asking: when do I use which, and why. This is Episode 2 of the Prove It series on Abelara Ascent, building toward the live reference architecture at the Prove It conference. About the Speakers Dylan DuFresne leads architecture and digital transformation engagements at Abelara. Zack Scriven hosts Abelara's podcast and livestream content. Both are preparing Abelara's Prove It booth — a full Enterprise B reference architecture running locally on-site at the conference. Key Topics The "motor overheating" problem that explains what data ops actually isEach platform's native home turf — composable SCADA, analytics, edge, integration, cloud-native MESHighByte vs Flow: data in motion vs data at restThe Prove It Enterprise B architecture — 3 sites, 5 platforms, different combinations per siteFuuz security: single outbound tunnel, no third-party surfaceRapid-fire: when NOT to use each platformPricing reality across all five vendorsSESME / SMIPS: the interoperability initiative for shared data models Key Takeaways Start with a problem, not a technology. Every digital transformation that skips this tends to fail.Data in motion → HighByte. Data at rest → Flow. Device connectivity at scale → Litmus. Plant-floor visibility → Ignition. Cloud-native enterprise backbone → Fuuz.For small companies without process maturity, a clipboard and Excel beat any of these tools. People, process, technology — in that order. Notable Quotes "HighByte is for data in motion and Flow is best for data at rest." — Dylan DuFresne "For the really small companies, a good process is way more important than the tools you're using." — Dylan DuFresne "It's people, process, and technology in that order for a reason." — Dylan DuFresne Timestamps [00:00] — Welcome + Prove It series recap[04:44] — The five platforms and their native homes[15:01] — Why more platforms doesn't mean more data models[18:35] — HighByte vs Flow: data in motion vs at rest[23:19] — The Prove It Enterprise B architecture walkthrough[28:26] — Fuuz security: the single outbound tunnel[37:24] — Rapid fire: when NOT to use each platform[44:23] — Pricing reality check[48:54] — SESME / SMIPS and the interoperability vision

    53 min

  4. 20 APR

    Live Architecture Review with Dylan DuFresne

    Abelara Lead Architect Dylan DuFresne walks Zack Scriven through the multi-site industrial automation stack Abelara planned and deployed for its Prove It 2026 sponsorship — naming specific vendors at every layer of the stack and explaining the architectural reasoning behind each choice. Starting at the edge (Opto 22 controllers), moving through site-level infrastructure (Ignition, TimescaleDB, Flow Software, TimeBase), into data operations (HighByte, Litmus Edge), across the enterprise UNS (HiveMQ broker), and up through multi-site enterprise applications (Fuuz, MaintainX, Google Cloud), Dylan builds the architecture layer by layer and takes live audience questions throughout. The through line isn't the specific tool list — it's the *why* behind each decision. Why a separate tag server in Ignition 8.3 for DevOps isolation. Why HighByte for data in motion but Flow Software for data at rest. Why vision for SCADA but perspective for MES. Why the blue-vs-red namespace distinction matters. Why Fuuz sits where it sits. The result is one of the clearest end-to-end walkthroughs of a real, deployable Industry 4.0 stack you'll find. Three things to take away 1. "Edge" means whatever the vendor wants it to mean — know what they mean.** Dylan's working definition: *"Edge is shorthand for as far into the stack as I care to look."* To a cloud vendor, the entire plant is the edge. To an OT engineer, it's the PLC. When a product labels itself "edge," you have to ask which edge. 2. HighByte for data in motion, Flow Software for data at rest.** The two tools live at the same layer of the stack, but do different jobs. HighByte is the ETL / data ops engine — pulling data from disparate sources, modeling it, moving it. Flow Software is the analytics engine — pulling data at rest from multiple stores and calculating KPIs against it. Not an "or" decision; an "and" decision. 3. Fuuz is to the enterprise what Ignition is to the site.** If Ignition is the Swiss Army knife platform for the plant floor — SCADA, MES, IoT connectivity — Fuuz is the same kind of platform for L3/L4 enterprise apps: iPaaS foundation, MES, WMS, supply chain. Different jobs, different data models, both Swiss Army knives at their respective layers. The stack, in one pass - Device layer (L0/L1): Opto 22 controllers - Edge connectivity: Ignition Edge (IOT licenses), running on bare-metal Linux or Docker - Site SCADA: Ignition Vision (for local multi-monitor operator screens) - Site MES: Ignition Perspective (for browser-based MES frontends) - Site tag server: Ignition 8.3 dedicated tag server — single source of truth for site current state - Historian: TimeBase (Flow Software) — telemetry, scalar data, in-flight time series - MES database: TimescaleDB on Postgres — contextual event data, state changes, tabular MES functions - Analytics: Flow Software — connects all the above, calculates KPIs, contextualizes - Data ops (Site A): HighByte — ETL from tag server to UNS broker - Data ops (Site B): Litmus Edge — standalone data pipeline, no local SCADA/MES needed - Enterprise UNS broker: HiveMQ (the Prove It shared broker) - CMMS: MaintainX - Enterprise apps / L3: Fuuz — MES, WMS, supply chain, ERP integration, multi-site consistency - Data warehouse: Google BigQuery / Google Cloud - Deployment: Portainer Timestamps:00:00 — Intro + the planned stack 05:11 — The credibility moment: "All 8 title sponsors, by coincidence" 07:45 — Edge devices, Opto 22, and why IPCs run Linux 13:00 — "Edge is shorthand for as far into the stack as I care to look" 15:16 — The Ignition 8.3 tag server 18:02 — TimeBase vs. TimescaleDB, MES core vs. MES custom 24:51 — SCADA in Vision, MES in Perspective — why 27:31 — Medallion architecture, HighByte, and the enterprise UNS 34:34 — Fuuz as the enterprise Swiss Army knife 45:09 — Q&A

    49 min

  5. 18 APR

    Digital Transformation isn't a product

    Summary Zack Scriven sits down for an impromptu conversation with Dylan DuFresne (Lead Architect & Co-founder, Abelara) on three of the industry's most-abused terms: "digital transformation," "unified namespace," and "Industry 4.0." Dylan's core argument is that the terms themselves are buzzwords — vessels that vendors fill with whatever they're trying to sell. The only useful question is what problem are you actually solving, and the only useful follow-up is what is this vendor actually selling me. The conversation moves from meta-critique into practical territory in the second half: Dylan walks through what a UNS has actually meant for the industry over the last decade (short answer: education), whether greenfield and brownfield sites need different answers (yes), and which tools he'd pick today if he were starting from scratch. It closes with one of the cleanest vendor-selection frameworks you'll hear on a podcast — and a discovery-call CTA for anyone who wants to talk through their own architecture. Three takeaways "Digital transformation" is whatever the vendor needs it to be to close the sale. The term has meant ERP-to-cloud migration, workflow digitization, knowledge-base digitization, and now unified namespace. The throughline isn't technical — it's commercial. If you're buying "digital transformation," demand to know what product or service is actually being delivered, and whether you have a problem it solves.UNS is a tool, not an answer. The real value of the UNS movement was education. Over ~10 years, the UNS conversation did something no one argued against: it educated the market on the need to connect ERP to plant floor, and share data across layers that never shared it. But "I want a UNS" is still the wrong starting question. Greenfield deserves a UNS-shaped architecture. Brownfield with working historians usually does not.Pick tools by problem, pick vendors by partnership. Dylan's ideal greenfield stack: Ignition, HiveMQ, Flow Software, Solace — some combination gets you most of what you need. Broker market has commoditized; the differentiation is adjacent features and culture. When two vendors solve the same problem, pick the one who wants to grow with you — not the one with the nicer salesperson. Chapters 00:00 — Cold open + intro  00:32 — What "digital transformation" actually means (and who benefits from the ambiguity) 03:56 — Why digital transformation is change management, not a product  05:08 — Unified namespace: what it is, what it became, what it's worth  08:30 — Greenfield vs. brownfield — and the real value of UNS  14:56 — Who actually benefited from the UNS movement  17:27 — The stack Dylan would build today (+ CoreFlux deep dive)  19:24 — How to pick vendors when products overlap  24:41 — Discovery calls + weekly architecture Q&A

    26 min

  6. 17 APR

    Bridging the ERP / Plant-Floor Divide — How Fuuz Created a True MES and a Bumblebee Culture

    SummaryGlenn Gardner (Abelara co-founder) sat down with Craig Scott (Fuuz CEO) at Fuuz HQ after spending a week embedded in bootcamp with the Fuuz team. The conversation threads through three topics: the unusual culture Fuuz has built around genuinely caring about manufacturing, the architectural decision to be the MES "shim" between ERP and the plant floor, and how democratized plant-floor data changes work for the personas nobody usually builds for — finance, accounting, and maintenance. About the guestCraig Scott — CEO and founder of Fuuz, a manufacturing operations platform purpose-built to unify ERP, plant floor, and operational workflows in a single data layer. Background spans CNC and robot programming, owning a manufacturing shop, and running a systems integration practice before Fuuz. Three takeawaysCulture is a hiring choice, not a slogan. Fuuz didn't hire developers who already knew manufacturing. They hired strong developers and put them on real implementation projects, forcing them to learn manufacturing by solving actual customer problems. Their CTO Lance now runs a maker space on the side.ERP and plant floor are different data models — stop trying to merge them. ERP is relational, transactional, 300 transactions/day. Plant floor is scalar time series, thousands of data points per second. Predictive maintenance is vector matrix tensor. You can't force all three through one pipe. What's needed is a unified data layer (the "shim") that speaks all three natively.The forgotten personas are the highest-leverage users. Finance and accounting teams burn cognitive cycles trying to reconstruct variances with spreadsheets. Maintenance teams can't get their predictive data to the enterprise. A platform that democratizes plant-floor data to those personas is worth more than another BI dashboard.Notable quotes"I found the park of people like me." — Glenn Gardner, on the Fuuz team's culture "ERP doesn't have to be those things, but there has to be that shim, that MES layer in there." — Craig Scott "I still have ulcers from those periods." — Glenn Gardner, on quarter-close variance hunting Chapters00:00 — Cold open: MES theory vs. reality00:38 — The Bumblebee culture metaphor03:37 — Why Fuuz hired devs and taught them manufacturing09:26 — What kind of SI Fuuz was, and how Fuuz emerged13:00 — The MES shim explained (ISA-95 / Purdue layers)17:11 — Why iPaaS approaches fail19:10 — Scalar vs. time-series vs. tensor data21:57 — 300 ERP transactions vs. millions of telemetry events24:08 — The AWS outage and Fuuz's architectural resilience25:11 — Predictive maintenance and the vector-tensor database problem28:25 — Democratizing data to finance and accounting31:19 — The "ulcers" story — quarter-close variance chasingLinks & resourcesFuuz: https://www.fuuz.comAbelara: https://www.abelara.comCraig Scott on LinkedIn: https://www.linkedin.com/in/craigascott1/

    33 min

  7. 15 APR

    How Fuuz Changes Everything — A Deep Dive Conversation

    Summary The Abelara team — Glenn Gardner, Zack Scriven, and Dylan DuFresne — just spent a week at Fuuz corporate headquarters for bootcamp. In this roundtable debrief, they give their unfiltered take: what they loved, what needs work, how Fuuz compares to Ignition and Plex, where it fits in the stack, and why a greenfield site should probably run both Ignition and Fuuz together. The conversation covers real pricing comparisons, the MCP tooling announcement, and why "it does everything" is both Fuuz's greatest strength and its biggest go-to-market challenge. Key Topics Covered What each team member is most excited about after bootcampWhat Fuuz needs to improve: UX, user journeys, discoverability of featuresFuuz vs. Ignition: not competitors — different layers of the stackFuuz vs. Plex: why enterprises evaluating Plex should look at FuuzPricing reality: single-site MES is comparable to Ignition; multi-site is where Fuuz pulls aheadEdge gateway architecture: cloud platform with an on-prem edge componentMCP tooling: Fuuz is building it now while others have only announced itThe three pillars: schema designer, flow designer, screen designerWhy "it does everything" is both the value prop and the sales problemBuild vs. buy spectrum: Fuuz as the middle ground between full custom and rigid off-the-shelf Key Takeaways Ignition owns the lower stack (SCADA, plant floor). Fuuz owns the upper stack (enterprise MES, iPaaS, ERP integration). A greenfield site should run both — they're best friends, not competitors.Fuuz's hardest problem isn't the product — it's explaining the product. It's six or seven commercializable products in one platform, and nobody can pitch that in a sentence without sounding like BS.MCP tooling on the Fuuz flow designer means a lot Notable Quotes "Ignition and Fuuz should probably be the best of friends." — Dylan DuFresne"It's like seven different applications. And if someone said pitch me on Fuuz, I would sound like an idiot." — Glenn Gardner"Other leading platforms have announced the ability to do this in the future. Fuuz is doing it now." — Dylan DuFresne (on MCP) Timestamps / Chapters [00:00] — What stood out most from Fuuz bootcamp [01:56] — Zack: enterprise orchestration and best-of-breed integration [03:08] — Dylan: the people, the platform, and where Fuuz fits in the stack [04:48] — Honest critique: what needs to improve [06:48] — The discoverability problem and the change logging trap [09:31] — Edge gateway explained: cloud platform with edge component [13:02] — "Fuuz is like six or seven different products" [15:12] — Pricing reality: Fuuz vs. Ignition vs. enterprise iPaaS [17:47] — Single-site vs. multi-site: where Fuuz takes the lead [20:06] — Ignition and Fuuz: complementary, not competitive [21:44] — Fuuz vs. Plex: entirely different platforms [23:29] — What module would you add next? SCP. [24:40] — The most common problem: integrating ERP with the plant floor [32:55] — MCP tooling: the AI unlock [33:41] — Glenn's final take: card-carrying Fuuz fan Links & Resources Fuuz: fuuz.comAbelara: abelara.comIgnition: inductiveautomation.com

    34 min

  8. 15 APR

    From ERP to Factory Floor — How CIOs Are Powering Modern Manufacturing with Fuuz

    Summary Glenn Gardner frames the quality problem every manufacturer faces: DPPM spikes and nobody can figure out whether it's a catastrophe or a blip — because the data lives in a dozen different systems. Steve Modrall walks through how Fuuz solved this for HighBar, the world's first solar-powered steel mill, deploying MES, WMS, yard management, scale house, and vendor portal in nine months. Craig Scott demos Fuuz's schema designer and shows how embedded quality checks and digital work instructions eliminate the "more training" corrective action that plagues every 8D process. Key Topics Covered Quality as the hardest problem in manufacturing: tracking DPPM across downstream, midstream, and upstreamWhy ERP falls down for midstream and upstream quality dataHighBar Steel: world's first solar-powered steel mill, 2x output per FTE vs. industryRed data vs. blue data: enterprise governance vs. plant-level detailiPaaS as the bridge between ERP and plant floor (not point-to-point)WIP visibility without SKU proliferationSchema designer: modeling manufacturing data as normalized relationshipsPoke-yoke through MES: embedding quality into process, not as an afterthought8D root cause failures when you run out of dataMCP integration for AI/LLM analysis on manufacturing data Key Takeaways The ERP handles downstream data (RMAs, customer returns) well, but for midstream (factory floor) and upstream (supplier quality), you need MES, SCADA, and quality systems — the ERP was never designed for that level of detail.Don't track WIP in the ERP — it explodes your SKU count by an order of magnitude. Keep raw materials and finished goods in ERP; let the MES own the WIP detail.If your 8D corrective action says "more training," you've run out of data. Embed quality checks into the process so the failure literally cannot propagate forward. Notable Quotes "Your business doesn't happen in the ERP. It happens on the plant floor." — Zack Scriven (quoting Walker Reynolds)"You start making stuff up because you're out of data." — Glenn Gardner (on 8D failures)"They're running this mill with half the staff and generating double the output per FTE." — Craig Scott (on HighBar) Timestamps / Chapters [00:16] — Welcome and introductions [01:34] — Glenn: the manufacturing reality check [03:02] — Quality as the most direct impact to revenue, margin, and customer sat [05:14] — Downstream data: ERP handles RMAs well [06:30] — Midstream: where ERP falls down [08:20] — Upstream: supplier quality [12:08] — "Your business happens on the plant floor" [13:22] — Steve: HighBar Steel case study [15:35] — Fuuz iPaaS: agnostic integration vs. point-to-point [24:08] — Craig: MCP and AI/LLM on manufacturing data [27:47] — Why serial-level detail doesn't belong in the ERP [30:28] — Fuuz as the unified namespace for this architecture [34:34] — WIP in ERP = SKU hell [36:21] — Red data vs. blue data explained [40:45] — Craig: live demo of the schema designer [54:00] — Poke-yoke through MES [57:09] — ISO 9001: embedded procedures vs. printed SOPs [59:29] — The drunk guy looking for his keys: why 8Ds fail Links & Resources Fuuz: fuuz.comAbelara: abelara.comOracle NetSuite: netsuite.com

    1hr 3min

  9. 14 APR

    The Golden Triangle: PLM, MES and ERP with Steve from Fuuz

    Summary Glenn from Abelara visits Fuuz corporate headquarters during boot camp week and sits down with Steve to walk through the real manufacturing pain points that Fuse solves — from the supply chain and factory floor divide, to quality traceability, bill of materials wars, real-time variance tracking, and the multi-plant standardization trap. Steve frames Fuse as the system that lives "where the carpet meets the concrete." About the Guest Steve is a senior leader at Fuuz with deep manufacturing operations experience. He positions Fuse as a composable platform covering MES, WMS, quality, scheduling, EDI, and iPaaS integration — designed to complement ERP rather than replace it. Key Topics Covered The supply chain vs. factory floor divide: pegging sales orders to work ordersERP's visibility gap below the shop floor levelQuality traceability: tracking components from dock to shipmentRecording PLC parameters per serial number for root causeThe bill of materials war: supply chain, manufacturing, and R&D viewsThe golden triangle: PLM ↔ MES ↔ ERP integrationReal-time variance tracking by work center and operatorMulti-plant standardization without forcing ERP onto the floorReducing tech stack from 40 vendors with a composable platformBalancing corporate control vs. local plant innovation Key Takeaways Pegging sales orders to work orders lets planners make partial shipment decisions in real time — most systems produce blanket work orders blind to customer demand.The million-unit recall problem exists because companies test everywhere but trace nowhere — traceability is the missing layer, not more testing.Use ERP for financials and front office; use MES for the shop floor. Forcing ERP down to the plant floor is why no enterprise has ever achieved one-ERP standardization. Notable Quotes "Where the carpet meets the concrete — that's where Fuse takes over." — Steve"The money's made and lost on the shop floor." — Steve"No two machines are alike. Even from the same manufacturer, they're all different." — Steve Timestamps / Chapters [00:00] — Inside Fuse HQ: a software company that knows manufacturing [01:34] — The supply chain and factory floor divide [03:14] — Pegging sales orders to work orders [04:30] — ERP's visibility gap on the shop floor [06:55] — Quality: the hardest challenge in manufacturing [08:09] — Tracking components from dock to shipment [09:48] — The million-unit recall problem [11:05] — Recording 120 PLC parameters per serial number [12:48] — What R&D leaders really need from production data [14:18] — The bill of materials war [15:29] — The golden triangle: PLM, MES, and ERP [18:53] — Real-time gross margin and variance tracking [21:42] — IT's challenge: future-proofing manufacturing [24:04] — The multi-plant standardization trap [27:49] — Employee development across standardized plants [29:48] — Closing thoughts Links & Resources Fuse: fuse.comSteve Modrall: LinkedInGlenn Gardner: LinkedInAbelara: abelara.com

    30 min

  10. 14 APR

    The Ignition Reference Architecture for Modern Manufacturing with Dylan DuFresne

    Dylan DuFresne walks through Abelara’s reference architecture for modern industrial systems — from edge controllers through Ignition’s tag gateway pattern, UNS publishing, historian integration with Timebase, Flow Software for contextualization, and enterprise-scale deployment with HiveMQ cloud bridging and Fuuz as an MES layer. The episode covers how to phase these components in with zero technical debt and how Abelara helps enterprises cut through analysis paralysis. About the GuestDylan DuFresne is an architect at Abelara specializing in Ignition, MQTT / Unified Namespace, and enterprise data systems. Key Topics CoveredTag gateway pattern: separating tag providers from front-end / back-end DevOpsIgnition 8.3 improvements and Gateway Area Network updatesHistorian integration: Timebase direct from tag gateway vs collectorsFlow Software for contextualization, KPIs, and bidirectional flowBlue namespace vs red namespace: site flexibility vs enterprise standardsHiveMQ cloud bridging to Snowflake, BigQuery, AzureFuuz as an MES layer replacing ETL between ERP and site systemsPhased implementation: SCADA → UNS → historian → analytics → AIKey TakeawaysUse a dedicated tag gateway so front-end and back-end systems can run DevOps cycles without risking production tag state.Standards should get stricter as you move up the stack — fluid near controllers, rigid near ERP.Build additively with zero technical debt: SCADA, then UNS, historian, analytics, AI.Timestamps[00:00] Tag gateway pattern [02:42] Timebase historian [04:01] Flow Software [07:45] HiveMQ + cloud data lakes [13:04] Fuuz as enterprise MES [15:06] Zero technical debt roadmap [17:50] Abelara workshops LinksAbelara: https://abelara.com Ignition: https://inductiveautomation.com Flow Software: https://flowsoftware.com Timebase: https://timebased.io HiveMQ: https://hivemq.com Fuuz: https://fuuz.com Litmus: https://litmus.io Axilon: https://axilon.com

    21 min

  11. 14 APR

    Dan Prudhoe — Why MQTT Wasn't Enough for Enterprise Manufacturing

    Dan Prudhoe spent 15 years building industrial systems at a large chemical manufacturer — scaling from beta Ignition in 2009 to 70+ gateways across 30+ sites. In this ICC 2025 conversation, he walks through replacing a legacy Unix MES with Ignition, adopting Spark Plug B and MQTT, hitting MQTT's limitations, and building an enterprise event mesh with Solace that streams millions of tags from edge to cloud. About the Guest Dan Prudhoe is a Senior Solutions Engineer at Solace. Previously he spent 15 years at a large chemical manufacturer leading Ignition adoption from beta, building a standardized platform across 30+ sites, and architecting an event mesh for millions of historized tags. Key Topics Covered Ignition from beta (2009) to enterprise-scale across 30+ plantsBuilding modular, upgradeable standards across diverse sitesSpark Plug B and MQTT: decoupling systems, lightweight data collectionMQTT limitations for transactional and guaranteed deliveryEvent mesh with Solace: edge to cloud, multi-protocol, guaranteed messagingSelf-service analytics with SeeqUNS debate: centralized semantic layer vs. composable hierarchiesGraph databases and industrial data modelingThe path: self-service → automated → autonomous (agentic AI) Key Takeaways Start with analytics, not SCADA — lower risk, proves value fast, builds political capital for mission-critical systems later.Build standards designed to flex — the first few deployments will break your standard, and that's expected.The path to autonomous manufacturing: self-service (SMEs solve their own problems), automated (event-driven workflows), then autonomous (agentic AI investigates and prescribes). Notable Quotes "We wanted to build a standard that's meant to have flexible standards." — Dan Prudhoe"Instead of we don't have enough data, they're almost like oh my god there's so much data." — Dan Prudhoe"We were able to allow them to start solving their own problems." — Dan Prudhoe Timestamps / Chapters [00:00] — Who is Dan Prudhoe? [01:06] — Ignition beta testing in 2009 [02:20] — MES 101 [05:10] — Scaling to 70+ gateways across 30 sites [08:53] — In-house vs. system integrator [11:01] — Ignition becoming enterprise-grade [12:00] — From Spark Plug B to event mesh [15:14] — MQTT's limitations [16:51] — Solace: edge to cloud architecture [20:55] — Self-service analytics for SMEs [26:31] — Predictive maintenance data provisioning [28:30] — The UNS debate [32:08] — Graph databases and ontology [33:42] — Wrap-up Links & Resources Solace: solace.comDan Prudhoe LinkedInIgnition: inductiveautomation.comFlow Software: www.flow-software.comSpark Plug B: sparkplug.eclipse.orgAzure Data Explorer: azure.microsoft.com/en-us/products/data-explorer

    34 min
  • 11 Episodes

About

Abelara Ascent - Long-form conversations about what it actually takes to modernize manufacturing. Abelara Ascent is where architecture meets execution. Interviews with the people building real systems. Panel discussions that go deeper than the keynote. And solo episodes that break down the frameworks, decisions, and trade-offs behind industrial digital transformation. Hosted by Zack Scriven, Director of Sales and Marketing at Abelara, with regular appearances from cofounders Dylan DuFresne, Chief Architect, and Glenn Gardner, President. If you are a manufacturing leader, plant manager, controls engineer, or solutions architect trying to figure out where to start, what to prioritize, and who to trust, this is the show. Published by Abelara. Event coverage powered by Abelara Live.

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  • Creator
    Abelara
  • Years Active
    2k
  • Episodes
    11
  • Rating
    Explicit
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    © 2026 Abelara