Unlocking the Hidden Factory: Tri Tech Automation on Finding Untapped Capacity in Plants and Their Own Panel Shop

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Overview

This episode of Manufacturing Happy Hour was recorded at Urban Chestnut Brewing Company in St. Louis. Host Chris sat down with three leaders from Tri Tech Automation, a control systems integrator: President Adam Ruebsam, Managing Director Luke Manier, and Ryan Williams, Director of Innovation and Solution Sales. The conversation centered on the "hidden factory." The team uses the term for the untapped potential inside a manufacturer's existing people, equipment, and floor space. Their position is that most manufacturers can get considerably more out of what they already have, usually by starting with people and data rather than new technology. They also argued that the same idea should shape greenfield plant design and applied it to their own panel-building operation.

22 min read

Starting Out: Business Value Before Technology

Chris started his career alongside Adam and Luke around 2010, when all three were in Rockwell sales in St. Louis. He described the two as among his earliest mentors, so he opened by asking what lessons from that period have stayed with them.

Adam said the biggest lesson was to put business value first and technology second. At a company like Rockwell, with strong technology to sell, it is tempting to lead with the coolest product. His lesson was to start instead with the customer's business outcomes, figure out what the customer needs to achieve, and then "rightsize" the technology to fit. He admitted this is hard when you have exciting technology you want to talk about.

Luke agreed. He added that early in his career he came to understand how much manufacturing matters to the national economy and to the communities around individual plants. He said he did not grasp that impact when he first entered the industry, and that it has fueled him ever since. For him, the work is about helping others solve problems and create impact, and knowing that the cause matters is inspiring.

Chris said he did not appreciate manufacturing's importance until seven or eight years into his own career. At the time he was working in the Bay Area while his friends worked in software and tech. He noted that the current enthusiasm for manufacturing and manufacturing startups was not there when he started. He also recalled his first week in the St. Louis office, when he had come from engineering and quality roles. Adam, Luke, and others seemed to put their full attention on getting him up to speed. Looking back, he said this taught him that investing heavily in new talent early, even if it disrupts your own plans for the week, makes people self-sufficient much faster.

Ryan Williams' Path Through the Industry

Ryan has worked in project management, engineering, and now business development. Chris asked what allowed him to move between those roles. Ryan said that, like Chris, he has a mechanical engineering background. He started at a small integrator doing mechanical design. The company could not keep him busy, so he picked up PLC programming to fill the time, with help from a couple of good mentors. He said he fell in love with system integration, PLC programming, and automation. He then finished college taking electrical electives. The common thread, in his telling, is loving every corner of system integration and controls and never being afraid to take on new technologies or new vertical markets.

What Tri Tech Does, in 30 Seconds

Chris asked Adam how he would describe the company to someone at the bar. Adam said Tri Tech is customer-focused first. He called the team "our intellectual property": the people are what make the work happen. He described the company as combining the team's passion, drive, and experience with a business-first conversation with the client, again rightsizing the technology. The aim is to help clients win in their global markets. His reasoning was that clients who are winning invest, and that creates opportunities for Tri Tech to earn their business.

Defining the Hidden Factory

Luke had first raised the hidden factory concept when the episode was being planned, so Chris asked him to define it. Luke described it as "the untapped potential to do more in their operations with the resources that they have." In his account, it includes invisible inefficiencies, unused capacity, and hidden problems and opportunities that most manufacturers struggle with. Some companies know they have these issues but do not know how to quantify them or go after them. Others have challenges they are not aware of at all.

He placed this against the pressures manufacturers face: constant demands to reduce costs, bring new products to market faster, and stay agile in a more globally competitive environment. He said the concept resonates with customers because it makes the problem feel real. It also lets the team identify specific focus areas that will produce results and that people can act on.

Luke stressed that the idea is not only for optimizing existing plants. It also applies to companies planning large greenfield or brownfield expansions. In those cases the conversation becomes more proactive. The question is how to involve the right people, especially the operators who have their eyes and hands on the process every day, early in the design of the process and control system. The goal is to give them the tools and visibility to spot improvement opportunities, so the new plant does not "recreate this hidden factory."

Chris said what appeals to him is that the framing tells manufacturers there is likely a lot of unused potential already in front of them. New technology may be part of the answer, but it is not a start from square one.

Finding It: Data, Quantification, and Justification

Chris asked Ryan how Tri Tech helps a manufacturer get more from existing assets. Ryan said the specifics depend on the customer. At a high level, though, it comes down to understanding what you have, which means data: collecting it, turning it into information, and using that to see where the hidden factories are.

Echoing Luke, Ryan said many customers already know roughly where their inefficiencies are. What they lack is the data to quantify them. So the work starts with data gathering, then analysis to find the low-hanging fruit with the biggest potential improvements. Many customers are deciding whether to invest in an expansion, an addition, or a new building, or whether they can get more from what they have. Tri Tech helps identify the opportunities, works with the customer through the capital process to justify projects, and then proves the ROI afterward. Ryan's main point was that customers usually know they have issues and want upgrades. They fall short on quantification and information, and that makes projects hard to justify.

Adam added that this is part of Tri Tech's digital transformation practice. The practice helps customers get intelligent assets and data, and makes that data informative enough to support business decisions. Most of the time, he said, the underlying problem is that customers do not have the data at their fingertips.

The Most Common Starting Point: The Workforce

Chris asked whether there is low-hanging fruit the team sees over and over during assessments. Luke said the common theme is people and workforce. Everyone in the industry faces the same shortage of skilled labor and the same unfilled jobs. So a common place to start is fully empowering and enabling the workforce a company already has. He listed examples:

  • guided work instructions
  • a different approach to training
  • decision support tools and dashboards

The goal is to help the people who interact with the process every day either prevent hidden inefficiencies or quickly diagnose and fix them when they occur. He added that an empowered, educated workforce can also find improvement opportunities on its own.

Chris said this surprised him somewhat. When the workforce topic came up, his mind went to modernization and analytics, not to equipping the existing team with tools like guided work instructions.

Ryan agreed that workforce is probably the top issue they see. He pointed to the "silver tide" of retiring workers taking knowledge out of plants and to less-experienced people coming in. He also emphasized operator empowerment through HMIs and diagnostics, so that operators can resolve problems without a technical person having to dig into PLC programs.

A Real-World Example: A Data-Hungry New Owner

For an external example, Ryan described ongoing work with a global manufacturer he did not name. The company had changed ownership. The new leadership was more data-hungry and wanted to understand the details of the manufacturing process, including its efficiencies and inefficiencies. Tri Tech was brought in for the upfront analysis: working out where the company stood on its digital transformation roadmap and how to get from point A to point B.

According to Ryan, the company has three facilities worldwide. The first has seen some immediate improvements, Tri Tech is now rolling the work out to the second, and a third remains. He described the work as largely dashboarding and exposing information. The customer thought it knew where its inefficiencies were, but seeing them on dashboards with real-time information is, in his words, empowering them to make real changes.

Top Ways Manufacturers Are Unlocking the Hidden Factory

Chris asked each guest to name one of the top ways they see manufacturers unlock hidden capacity.

Luke first repeated worker enablement. He then built on Ryan's example. A key part of the solution for that global customer was connecting ERP data (orders, material flow, and coordination of assembly across international sites) with plant performance. While Tri Tech works at the equipment level to enable operators, it also pulls the right data from the ERP and combines it with OT-level system data. Luke sees this as a large opportunity for many manufacturers.

Ryan pointed to OEE applications on packaging lines, along with quality projects that expose data on quality and product rejection to reduce bad production. He said there is room for improvement on almost any packaging line. If there truly is none, he joked, it may be time to build that greenfield plant. He named OEE as one of the main areas where hidden factory potential starts to appear.

Adam said he struggled to pick one because every customer's journey is different. Drivers vary by industry, regulations, company size, scaling needs, quality and yield, and people. You cannot walk in and say you need to look at the network, data collection, or modernization. There is no silver bullet and no "Industry 4.0" part number to hand over. He said that is what makes the work fun. He also noted that customers sometimes get buried in their own ways of working, and an outside perspective helps.

Designing the Hidden Factory Out of Greenfield Plants

Chris returned to the greenfield question. The concept seems to apply most naturally to existing operations, so how does it work for new ones? Luke said many optimization opportunities in existing plants come from traditional approaches that left islands of automation, siloed data, and systems that evolved piecemeal. In a greenfield project, the proactive approach is to understand why manufacturers ended up with those invisible inefficiencies and design new systems differently.

Ryan said that when Tri Tech starts from a "patch of dirt," it can design information, connectivity, integration, and operator empowerment into the initial design. He gave several examples:

  • Integrated power, to get as much information as possible from drive and motor control systems.
  • Deep involvement in OT network design, so the network is expandable and robust and generates its own actionable information.
  • Library development. Whether a customer starts from a vendor library, such as a Rockwell system, or its own add-on instruction and object library, Tri Tech tries to evolve it into new standards with more operator empowerment.

The purpose, Ryan said, is to avoid burying a hidden factory that someone will have to uncover later.

Tri Tech's Own Hidden Factory: The Panel Shop

Chris noted that he tends to picture a widget manufacturer when he hears "hidden factory." Since Tri Tech is itself on a digital transformation journey, he asked Adam what that looks like inside the company.

Adam explained that Tri Tech has in-house design and manufacturing capability at its St. Louis and Tulsa locations. He said its manufacturing is not as complex as its clients', but at a high level it is similar. Panel fabrication is almost linear: to go from 1,000 panels a year to 2,000, you could double the square footage, the equipment, and the labor. But capital is not endless. He believes many clients face the same situation, with fixed equipment, fixed floor space, labor constraints, and limited capital. So Tri Tech concluded that its hidden factory is within its own four walls, using the people, equipment, and space it already has.

That led the company to create a three-year picture of a "paperless panel shop." Adam described it as a first step toward eliminating waste. Beyond removing paper, it improves communication both internally and with clients. He was candid that the team did not know exactly where it would end up or how it would get there.

They started with people: the fabricators, designers, and frontline managers who have the ideas. That meant encouraging a different way of thinking around lean, efficiency, and a willingness to try things and innovate. Once they had a picture of how to get there, they evaluated technologies. EPLAN became the first step on the design side, followed by smart production modules in the fabrication centers. Adam framed it as people, process, and technology, "just like our customers." He estimated the company is about a year into the three-year journey and making strong progress.

Asked why three years, Adam said Tri Tech had adopted EOS, the Entrepreneurial Operating System, as its business operating system, and the three-year picture comes from that program. It forces you to write down what you have in your head and set things in motion. He described it as a picture of where they want to go, not a detailed prescription of exactly what they will be doing in three years.

Two Sites, One Company: Consistency, Quality, Velocity

Chris asked whether the journey looks different in St. Louis and Tulsa, since multi-site manufacturers usually see differences between sites. Adam said the goal is for both to look the same. He named three guiding principles: consistency, quality, and velocity. On consistency, a panel should have the same look and feel whether it is built in St. Louis or Tulsa, "all the way down to the font" on labels and wires and the printers used. Tri Tech has been in the Tulsa market for about three years.

Adam said clients are ultimately trying to reduce risk when they engage with Tri Tech, and its people, process, and technology help with that. The value differs by client type. For OEMs, design consistency across panels reduces design time, which makes Tri Tech more competitive and speeds time to market. For large EPC firms, Tri Tech designs in a cloud collaboration environment, so the end user, the EPC, and the mechanical and electrical contractors share a single source of truth. Internally, the benefit is proven, repeatable standards. He compared this to PlantPAx-style libraries that are designed around and reused, which he said drives many efficiencies.

Luke called the two shops a concrete example of unlocking hidden factory value. Tulsa came through an acquisition. It brought a strong team with its own processes, reputation, and customers, and it was doing well, but the two sites did things differently. That created friction for everyone else. One project management team had to deal with two groups working two ways. Planners trying to optimize capacity had to work across both. Salespeople wanted quick insight into how fast the company could respond to a new opportunity. Standardizing helps inside each shop because a best practice or innovation in one site can easily be applied in the other. And to sales, project management, and design, the company now looks like one organization. Luke said Tri Tech is operating more efficiently as a result and is "on our path" to extracting that value.

From Serial to Parallel: Stitching the Technology Together

Ryan pointed out that the hidden factory is not always about inefficiency or labor. Sometimes it is simply the way the work is done. The tools Tri Tech introduced let it move panel manufacturing from a serial process to a partly parallel one. He asked Adam to explain the integration between EPLAN and the fabrication equipment: the CNC panel modification center and the wire machine.

Adam described it as an internal version of the islands-of-automation problem: several technologies that need to be stitched together. It starts at design, where components are selected and laid out. In the design platform, the team knows every wire's gauge, color, length, and label. When laying out the subpanel, it knows where every hole needs to go for the DIN rail and wire duct. The aim is to eliminate every keystroke on the shop floor. A file goes straight to the wire machine, which cuts and strips each wire, attaches a ferrule-like end, and prints and applies the label. Because everything exists in a 3D, digital-twin-type environment, DIN rail and duct can be cut to length at the same time.

He contrasted this with the old linear process: get the subpanel, lay it out, check for room, measure, cut the rail, assemble, wire, then QC. Now wires can be cut, the mod center can cut holes in the enclosures, and rail can be cut all at once, with everything brought together at the end. He called the effect on velocity "huge."

The next phase, Adam said, is to take the large amount of data this equipment produces and make it available. Internally, project managers should be able to see project status: where a job is, whether material is on hand, and whether anything is late. Tri Tech also wants to share that information with clients and with its suppliers and distributors as it consumes product.

Chris said this addresses how Tri Tech's own transformation benefits its customers: consistent output from both sites, plus the move toward sharing project data with clients. He said many manufacturers he talks with want this kind of transparency, with faster communication as well as faster projects. Adam tied it back to time to market and ROI: reaching a client faster with an optimized design increases the client's return.

Ryan added that Tri Tech faces the same workforce challenges as every manufacturer. With EPLAN and the connected-worker environment, a worker does not need to be a technically trained schematic reader; the work can be closer to "paint by number." He said this reduces the skill requirement for new hires and opens up a new talent pool of people who can do the job effectively.

A Lesson from the Savannah Bananas

For the wildcard question, Chris learned that two of the three guests had recently been to a Savannah Bananas game. He asked what manufacturers could learn from the team.

One guest joked that the lesson is to set a time limit and stick to it, referring to Banana Ball's two-hour game limit. Another described the event as a cross between a circus, a rock concert, and a baseball game. Luke said his kids called it overwhelming, sensory overload from the music, dances, and constant crowd interaction, and everyone left exhausted.

Luke's takeaway was how relentless the team is about delivering a great fan experience. He connected this to Tri Tech's work with partners, customers, and vendors, and said it fits the three-year picture Adam described, which also includes the customer experience that Tri Tech is trying to keep improving. One of the guests admitted he had never seen a connection between the game and their business until that moment.

Chris added his own view of the "fans first" philosophy. As he understands it, the idea is to list everything people hate about an existing product or experience and imagine it without those things. He cited Banana Ball's ban on bunting, which he said exists simply because bunting is disliked. He also mentioned that tickets in Savannah include free food, and told a story about pocketing an extra hot dog.

Advice for Newcomers to Manufacturing

Chris closed with a question for early-career listeners, who he said make up about a quarter of the audience. He extended it to people entering manufacturing for the first time from other fields, including those joining hard-tech startups or long-established manufacturers.

Ryan said not to be afraid to try new things, believe in yourself, find good mentors, and learn as much as you can from them. He talked about how rewarding it is to see how so many things are made and to watch something start up and come to life for the first time. He said he had no single piece of advice beyond finding someone great to learn from and loving what you do. The others joked that he had taken all the good answers.

Adam also stressed mentorship. He encouraged newcomers to reach out to technology providers, distributors, manufacturing partners, and integration partners, and to lean on them "early and often." He called manufacturing "very much a team sport" and said he thinks the whole industry is rooting for people to succeed. His summary: you are not alone, ask questions, and many people want to help.

Luke said he has had amazing mentors and still has some today. His advice was to stay curious and keep reinventing yourself. The industry is changing so quickly that what you know now may not carry you through your career. He said that if he is not continuing to grow, he will fall behind fast, and he finds that challenge motivating. Chris noted that Luke's point about still having mentors shows mentorship is not only for people just starting out, and called the "stay curious" advice very Ted Lasso.