Litmus CEO Vatsal Shah on Unified Industrial Data, Scale, and Cutting Through the Noise

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Overview

In this episode of Manufacturing Happy Hour, host Chris talks with Vatsal Shah, founder and CEO of Litmus, which describes itself as a unified platform for industrial IoT. The conversation covers why Shah thinks fragmented industrial data needs one end-to-end platform instead of a patchwork of point solutions, and what Shah learned on a recent round of customer site visits. Shah's main argument is that manufacturers now arrive with real, quantified problems. They increasingly treat scale, central management, and the cloud as requirements, not options.

16 min read

What "unified platform" means in plain terms

Chris asked Shah to explain Litmus as they would over drinks. Shah started with what they see as the core challenge in manufacturing and industry: a fragmented data landscape. Plants run legacy systems, and control systems, automation systems, and robotic systems all hold large amounts of data. The work is to collect that data, normalize it, contextualize it, and make it available to "smarter systems" that can consume it.

Shah argued that this whole journey has to be unified. If one vendor solves one piece and another vendor solves the next, customers are left to work out everything in between. Shah compared that to "playing giant Jenga." Litmus's pitch is a single platform that covers the full journey for industrial customers. For a less technical version, Shah used a simple picture: there is a boiler, you want to know what it is doing, and the unified platform is how you understand, analyze, and use that boiler's data.

From ladder logic to a connectivity problem

Before Litmus, Shah worked at Rockwell Automation in industrial design, business development, and strategy, according to the host's introduction. Shah described their career as starting right after a bachelor's degree, as an instrumentation and control engineer. In the first week on the job, Shah was handed P&ID diagrams and asked to develop SCADA screens and business logic. Shah said they were "fascinated" by ladder logic and kept building it, first for power plants and later for oil and gas, pulp and paper, and food and beverage.

As a junior engineer, Shah initially stayed at a desk rather than going out for field acceptance testing. Later they commissioned some facilities, which gave them experience with panel logic, HMI, and SCADA work on both the design and field sides.

The problem that led to Litmus came from one project that required working with four vendors, including large oil and gas automation suppliers such as Emerson and Fisher-Rosemount, as well as Siemens systems. By Shah's account, it took about three and a half months just to establish connectivity across all of them. The team used OPC and everything else available, and they still ended up writing Visual Basic scripts to pull data from one system and push it into another. The original idea for Litmus was a platform that could talk to every control system and output the data "in a way that humans can understand."

"49 out of 50 customers said you're naive"

Shah said the idea took shape around 2012–2013. It came mostly from their own and their co-founders' experience rather than from customer requests. The team then took the idea to customers quickly, and Shah recalled that 49 out of 50 told them it was naive, that it would never work, and that even if it did, nobody would buy it from them. The team kept asking why not. Over the following years they built a more compelling story in which connectivity was only one part, and how the data gets used became the larger part. Litmus was founded after that.

Chris asked what kept them going when roughly 98% of people were discouraging. Shah gave two reasons. First, the objections were never that the problem didn't exist. People said nobody had solved it before, and that if anyone did, it would be one of the large automation companies, not an independent vendor building a common data layer for industry. Shah took that to mean the problem was real. Second, Shah said the founders were "a bunch of young kids" out of university with nothing to lose and nothing to unlearn. Everything was new to them, which made them bullheaded. Shah admitted with some humor that the skeptics "of course knew what they were talking about."

Shah's advice to manufacturing leaders in a similar spot was to persevere. As Shah put it, if the problem statement exists, "you might be the best one to solve it because you identified it." Shah added that for Litmus the key ongoing challenge was to keep reaching product-market fit with a broader customer base.

Back on the plant floor after COVID

Chris mentioned a recent LinkedIn post in which Shah described visiting about six customers to see Litmus in use. Shah said visits like this were routine before the pandemic. The two or three COVID years went by in a blur of video calls. Being back on site reminded Shah how much ingenuity is built into manufacturing operations, which is easy to lose sight of while writing code on a laptop.

Shah gave an example. A developer might casually say "we're going to connect a million tags." Once you understand what those million tags represent in a facility worth a hundred million or a billion dollars, you stop using the phrase lightly. Shah described seeing their product influence a billion-dollar manufacturing operation as "mind-blowing."

On the question of what kind of manufacturer adopts this technology, Shah said these customers are not only early adopters but mass adopters, and that the market is ready. In Shah's view, the questions have become concrete: here are my assets, here are my processes, here is my problem, can data help solve it? Shah said "it's not fluff anymore." It is no longer about digitizing and seeing what happens.

Two concrete problems: yield loss and scrap

Shah described two customer problems from the trip.

The first was at what Shah called one of the largest food and beverage companies. The issue was in the packaging machines: why yield was below expectations and why downtime was higher than it should be. The company's KPI was manufacturing loss per hour. They compared the machines' specifications with actual performance and multiplied the gap by the value of the finished product. The result, as Shah relayed it, was about a billion dollars a year in lost manufacturing capacity. The company then asked whether data could help close that gap. Shah framed it as specification versus reality. Data could show where downtime happens and help prevent it, which directly increases yield.

The second was a metallurgy company with a scrap problem. When a product doesn't meet the quality they want, it is scrapped and made again. That wastes manufacturing resources, production resources, and human effort. The company wanted to reduce it. Shah called both of these "very genuine" problems.

Two kinds of customers, and a rough split

Chris asked whether customers arrive already knowing what a problem costs them, or whether Litmus helps them find out. Shah said both kinds exist.

The first kind starts with discovering the data. Shah's example was a pistachio factory that relied heavily on pen and paper, with handwritten logs for cleaning and other processes. Without digital records, the company couldn't see where to optimize. Companies like this build a baseline digital infrastructure: they collect the data, push it into a simple cloud data warehouse, and visualize it with tools like Power BI or Tableau. Once they can see things like a 100-kilogram loss on one run, or what a golden batch looks like, they start to identify which use case to pursue.

The second kind, like the food and beverage company, already knows the problem and the gap between spec and reality, and wants data to help solve it.

When asked for a rough split, Shah estimated 35–40% in the discovery group and about 60% in the group that already knows its problem. Shah immediately called this a possibly "very biased" figure. Litmus tends to engage companies that already have an industrial IoT or Industry 4.0 strategy, with an officer and a budget attached, so Litmus may enter late in the journey. Some of those companies may have been in the discovery group a year earlier. Chris saw the numbers as a positive trend compared with five or ten years ago, when many companies didn't know what their data was or where it lived.

Shah added that customers also understand the problem "one step deeper," as a technology problem. They know their environment is heterogeneous. No single vendor can solve everything, and they often can't even get one system integrator to connect everything or help design an architecture that will scale. Shah said some vendors had "borderline conned" these customers by selling solutions presented as scalable that weren't. As a result, customers now say they will only work with vendors that scale well, model their data, and put security first.

Technology-first experimentation: encouraged, but not on production

Chris raised a common problem in manufacturing digitization: people find an interesting technology and apply it before defining the problem. Shah said the response is mixed. Doers often start with technology, whether something from GitHub, an open-source project, or something they saw on LinkedIn. Shah said they should not be discouraged. They should experiment, play with low-code environments, build applications, and visualize data.

Shah drew a clear line at production systems, though. Hooking experiments up to production, or connecting them to a real boiler that could have serious consequences if it were hacked, is "probably not" something people should do. Shah's position: learn the technology and pick up new skills, but know enough to understand that it can be dangerous on the plant floor.

Who actually drives digitization: a "fusion" of teams

Chris noted that digital transformation is often seen as a C-level initiative and asked how plant-floor staff are driving innovation. Shah agreed with Chris's framing. By Shah's estimate, about 75% of the people they met on the trip began as industrial automation or automation engineers and now lead manufacturing digitization strategies, because they know what exists on the plant floor.

Across Litmus's customer base, Shah described CIOs or data officers bringing together three kinds of people: those who know the plant floor and have done PLC programming, data scientists who can interpret the data, and application builders. Shah called the combination a "fusion that you can't replicate anywhere else." Funding usually comes from the center, because rolling out data initiatives across 50, 100, or 200 plants requires a real budget. A single plant owner can drive the effort, but that person guides the central team on how to deploy, distribute, scale, and manage it, and on what the data means.

Chris said that in their own interviews, the companies that succeed at digital transformation have cross-functional teams of executives, IT, OT, and plant-floor staff. Shah said this applies to "100%" of Litmus's large customers. These teams sit under an umbrella program, such as a data initiative, a manufacturing DataOps initiative, or a CIO-led asset program, and include practitioners, data scientists, and application builders.

The surprise: scale is not optional

Asked what surprised them on the trip, Shah pointed to Litmus Edge Manager, the company's central management product. Litmus had positioned it for later, when customers were ready to scale. Customers and system integrator partners told Shah that scale matters much earlier than Litmus had assumed.

Shah relayed their reasoning. Plants already have legacy OPC servers, legacy SCADA systems, and home-grown aggregators built on custom code. These work, but they can't be replicated from one line to another or one site to another. If one site uses Node-RED and another uses something else, the central team has no practical way to manage it all. In Shah's summary, customers said scale and central management are "not optional" for any of their industrial IoT initiatives. Shah said this was not entirely surprising, but the way customers described it was.

Chris asked whether the "fusion" teams explain this. Shah said yes, at least partly: one part of those teams is cloud-native IT staff who are used to scripting everything and managing laptops, networks, and data warehouses centrally. They couldn't understand why OT tools were built to run on a single line and never designed for scale. One customer told Shah that a major reason for choosing Litmus was that Edge Manager lets them make one API call and update all of their nodes across every plant. As Shah recounted it, the customer said this was not a feature but a mandate, and that without it they would never use the product.

Cloud: fear has shifted from security to cost

Chris asked whether manufacturers are past their fear of the cloud. Shah said the fear used to be about attack surface: enabling cloud services might open up cybersecurity and management problems. Shah's view now is that "cloud is not optional anymore." The customers Litmus works with already have cloud initiatives on the financial, supply chain, ERP, and MES side, and have spent several years moving local SQL servers, MySQL databases, and ERP systems to the cloud. They have built trust and relationships with cloud providers. Now they are bringing operational data into the same environment.

Shah said a fear remains, but mostly among midsize companies, and it is about cost rather than security. They worry that turning things on could cost a million dollars once per-message charges and warehousing costs add up.

Feedback-driven development

Chris asked how to bring customer feedback to market quickly. Shah said "feedback-driven development" has always been a core principle at Litmus, and told a story from six or seven years ago. A large automotive tier-one supplier issuing an RFI asked whether Litmus had a particular connectivity capability, and said Litmus would be disqualified without it. The capability was already on Litmus's roadmap and existed in their lab, so they said yes. They arranged a call within two days and demoed it. Someone had worked 24 hours straight to build the connectivity overnight.

Shah believes feedback-driven development is "the only way to survive" as an industrial data platform, and called the company's accumulated feedback one of its biggest assets. Litmus holds quarterly business reviews with customers. Shah personally joins significant customer support calls to learn where customers hit the platform's limits or where ROI is being constrained. Internally, Litmus has a process for segmenting feedback from customers and channel partners and turning it into a product that meets many requirements at once. Shah called feature development "more like art rather than science": you take all the input, "create a gumbo out of it," and launch a feature that addresses about 80% of the issues from the start. Shah said the company has run this cycle for about six years and credits it for the company's success, describing the team as engineers first, close to the ground, who let customers tell them what to solve.

Closing thought: filtering the noise

Asked what they wanted to leave the audience with, Shah returned to the earlier topic of doers experimenting on their own. Shah said there is more noise in the market than people realize. Every problem has many proposed answers, some that mainly benefit a particular vendor, some that benefit the customer, and some that benefit the ecosystem. Shah thinks filtering that noise is critical. Sometimes you have to try things yourself. Otherwise, find a trusted partner who puts your interests first, whether a system integrator, technology partner, cloud partner, or value-added reseller. Shah said Litmus tries to answer in the customer's favor rather than in favor of its own architecture. Shah's answer to how to cut through the noise: try it, understand it, and find a trusted partner to help you get there.