Manufacturers know that automation is table stakes in 2025, and yet it’s still a bit of an afterthought for some. You’d think something that can make or break a facility would be everyone’s number one priority. And as you’ll hear in this episode, overlooking automation can sometimes have disastrous consequences.
In this episode, we sit down with Cassy Gardner and Chris Schleich from E Tech Group over virtual Pellegrinos to unpack a real-world case study. They were called in to revive a mothballed solar facility where the owners had accidentally destroyed critical automation infrastructure during demolition. Cut wiring, severed connections, damaged systems… all the stuff they didn’t realize was essential until it was gone.
The two walk us through everything from why Front-End Engineering and Design (FEED) studies matter (even when you’re racing against the clock) to how “humble confidence” became their project philosophy. You’ll hear about oversized electrical panels, “pit bull” project managers, and why sometimes the best sales strategy is just showing up when you say you will.
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3 Quick Things from this Episode
- Start automation earlier than you think. It may only be 10% of the spend, but it drives 90% of how the facility actually runs. Finding the right automation partner sooner in the process can save you from costly issues down the line.
- In fast-paced projects, discipline is more important than heroics. Focus on clear, functional specs, strict use of proven libraries, and a requirements owner who keeps specialists aligned.
- The best designs account for the unknown. Late-stage changes don’t have to break the schedules if you’ve already factored in flexibility. Be prepared to pivot when the demands of the customer or the market shift.
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Tweetable Quotes
- “Typically, in a large capital project, the automation budget is around 10%. But it’s a really critical 10% that you need to invest to have the manufacturing work the way you want to work.” – Cassy Gardner
- “Automation relative to mechanical, electrical process, etc. has an outsized impact.” – Chris Schleich
- “Always start earlier than you think you need to start. If you can engage a partner who is an expert in automation, you will set yourself up for a foundation of success.” – Cassy Gardner
Please Scroll Down for Recommended Resources from this Episode
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Hexagon is the global leader in precision technologies at any scale. Their digital twins, robotics, and AI solutions are transforming the industries that shape our reality. Learn how Hexagon is helping unlock next level innovation, bringing the power of automation, simulation, and real-time quality control to the smallest shop floor or the largest enterprise
What We Discuss with Chris Schleich and Cassy Gardner
- Why automation often becomes an afterthought in capital projects, and the surprising impact that has
- How automation may be a small slice of the spend, but determines how the plant runs
- The most common pitfall manufacturers face when it comes to automation planning, and the one piece of advice Chris and Cassy would share with them
- What a FEED study is, and why it’s essential in fast-paced manufacturing projects
- How “humble confidence” and “tenacious politeness” became guiding principles for the team at E Tech
- Real-life setbacks manufacturers face in automation: What happens when demolition destroys critical wiring and IO connections and how a hazardous monitoring partner failed mid-project
- Lessons any manufacturer can apply whether that’s running a project with 45 people or just five
Recommended Resources
- E Tech Group, one of the largest engineering and systems integration companies in the US, providing automation, control and information systems
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