Smart Manufacturing Made Affordable: Practical Industry 4.0 Solutions
- Jessica Duffield
- 2 hours ago
- 3 min read
During the Peak Performance Symposium, one of the most engaging sessions was the panel discussion “Smart Manufacturing Made Affordable: Practical Industry 4.0 Solutions,” moderated by Madison Lundy of the Smart Factory Institute. On stage, Mike Brooks, Industry Manager at Phoenix Contact; Jeff Jolley, President of Advanced Makers; and Jonathan Gonzalez, Co-Founder and President of FocustApps, shared how manufacturers can take realistic, cost-effective steps toward digital transformation — proving that Industry 4.0 isn’t just for large corporations with massive budgets.
Start Small, Think Big
Jeff Jolley, emphasized that embracing Industry 4.0 doesn’t require a complete overhaul. “There are ways to retrofit existing machines, collect meaningful data, and modernize without rebuilding an entire system,” Jolley explained. “Small sensors and low-cost integrations can provide powerful insights and management visibility.” The key takeaway: modernization can be incremental, allowing companies to realize immediate improvements while planning for long-term transformation.
The Power of Edge Computing
Mike Brooks of Phoenix Contact expanded on the idea of scalability, encouraging manufacturers to start at the “edge.”“You don’t need to send all your data across the organization,” Brooks said. “Start simple. Capture only what you need, analyze it locally, and act on it. You can implement solutions under $1,000 that deliver measurable impact.” He described edge computing as a gateway to smarter operations — enabling companies to harness data securely and cost-effectively without disrupting production.
Assess, Visualize, and Plan the Journey
Jonathan Gonzalez of FocustApps stressed the importance of starting with clarity. “The first step is knowing your current state,” he said. “Conduct an assessment, understand your systems and data, and define your future vision. Then create a roadmap with achievable milestones.”
Gonzalez noted that this approach helps manufacturers secure early wins while avoiding “pilot paralysis,” a common challenge where innovation efforts stall before scaling.
Sustainability Through Smart Data
Jolley also highlighted sustainability as a natural benefit of digital transformation. “Monitoring air consumption or energy usage can lead to major savings,” he shared. “By catching defects early or identifying inefficiencies, you reduce waste and improve both sustainability and profitability.”
From energy management to predictive maintenance, simple data-driven insights are helping manufacturers meet both operational and environmental goals.
Culture Over Technology
While the technology discussion was robust, the panelists agreed that culture and leadership are just as critical. "Many digital transformations fail not because of technology, but because of culture,” Brooks said. “If you’re doing this to your employees instead of with them, it won’t stick.”
Gonzalez added that celebrating small victories and involving employees early are vital to sustaining progress. “You have to build confidence at every step — that’s where the real transformation happens.”
Bridging Legacy and Future
The panel closed with a reminder that every manufacturer, whether a small regional plant or a global enterprise — can take steps toward Industry 4.0. As Brooks summarized, “Factories today are like the United Nations, every machine speaks a different language. Success comes from integrating those voices, not replacing them.” With tools like Industry 4.0 Assessments from the Smart Factory Institute and support from technology partners such as Phoenix Contact, , FocustApps, and Advanced Makers, the path to smart manufacturing has never been more accessible.
Interested in learning more or becoming a technology partner? Contact Madison Lundy at m.lundy@peakperformanceinc.com.