DigitalituM Podcast Episode 19 - Holger Schlaps - Steve Forrest - The Future of Manufacturing with AI

DigitalituM Podcast - At the Intersection of Manufacturing and Digital Transformation

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🎙️ DigitalituM Podcast Episode
At the Intersection of Manufacturing and Digital Transformation
Topic: The Future of Manufacturing with AI

Guests:
👤 Holger Schlaps, Head of R&D at SULZER GmbH
🔗 Connect with Holger on LinkedIn

👤 Steve Forrest, VP of Operations at AutoTool Inc.
🔗 Connect with Steve on LinkedIn

🎧 In this episode, host Markus Rimmele reconnects with Holger and Steve to expand on their recent panel discussion at the GACC SME Manufacturing Conference in Greenville, SC. The conversation dives into how AI is transforming manufacturing, from enabling smarter welding to closing the skilled labor gap with intuitive maintenance support systems.

💡 Key Topics Covered:

✅ AI in Manufacturing – Before It Was Cool
Holger shares how SULZER began working with AI in manufacturing back in 2018, long before the ChatGPT boom. His focus? Making AI practical by turning proof-of-concept efforts into production-ready solutions.

✅ The Real Problems on the Shop Floor
Both guests emphasize the twin challenges:

• A shrinking, aging workforce with less technical expertise
• Disconnected machines and siloed data that hinder efficiency and insight

✅ AI-Powered Solutions with Real-World ROI
Steve explains how AutoTool uses AI vision systems (like APERA.AI) to enable bin-picking in robotic cells, turning chaotic part orientation into automated efficiency.
Holger adds how AI-driven knowledge management systems help less-experienced operators act like seasoned pros, using tools they already have (smartphones, tablets).

✅ Use Case: AI for Weld Quality Inspection
Markus, Holger, and Steve walk through a joint AutoTool + SULZER project using AI and 3D profiling scanners to inspect welds. What makes it different?
Instead of just flagging a bad weld, the system diagnoses why it’s bad—and guides operators through corrective action.
This approach combines cloud-based AI, Programmable Logic Controllers (PLCs), and live sensor data to create a self-improving, closed-loop system.

✅ From Data Silos to AI Enablement
AI connects disparate systems—such as MES, ERP, PLC, and SCADA—into actionable intelligence. That unlocks predictive analytics, allowing manufacturers to shift from reactive to proactive strategies.

✅ In-Process AI for Welding Paths
Steve also introduces a second AI use case: in-process weld path correction, which utilizes cameras, touch sensing, and adaptive software. This is especially vital in heavy equipment manufacturing, where weld seams vary in position.
AutoTool utilizes tools such as Apogee and CAD-to-path solutions to automate seam detection and robot guidance.

✅ Maintenance AI: Empowering Operators
Instead of waiting for a maintenance tech, AI provides operators with step-by-step guidance to get production back online fast. AI serves as a 24/7 assistant, reducing downtime and improving efficiency.

✅ Workforce Readiness for AI
Rather than intensive retraini

Stay tuned for more inspiring conversations about manufacturing and digital transformation. Also, remember to follow and subscribe to the DigitalituM Podcast for exclusive insights from industry leaders and innovators.
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