Cybersecurity Remains Key Issue for US Manufacturers
In an increasingly digital world, the fear of an online attack is a sad reality that many people must deal with on a regular basis. For many, the worry might be that their personal financial information could be compromised and hard-earned money stolen.
On television and in movies, hackers usually target important government installations or large financial institutions. The sad reality, however, is that their targets are often seemingly innocuous companies that don’t seem like they’re particularly tech-savvy.
According to a Smart Industry article by Farès Sakka, the operational technology (OT) of manufacturers is often the target of hackers: “The U.S. has the highest concentration of OT-targeted cyberattacks anywhere in the world, accounting for a staggering 49% of all such incidents.”
Why are U.S. manufacturers so vulnerable to cyberattacks? Sakka believes the answer lies in the inherent conflicts between OT and information technology (IT) teams at manufacturers: “While IT often pushes for modernization and innovation, OT teams, responsible for the smooth operation of production lines, often resist change for fear of any disruption.”
Sakka notes that “U.S. manufacturing stands as a cornerstone of the American economy, yet it faces a critical internal challenge: the persistent friction between operational technology and information technology. This divide, characterized by differing priorities, technical languages, and even corporate structures, hinders progress and exposes organizations to significant risks.”
For example, “IT often pushes for modernization and innovation,” but “OT teams, responsible for the smooth operation of production lines, often resist change for fear of any disruption. Their reliance on legacy systems, while seemingly safe, has inadvertently created a breeding ground for escalating costs and, most alarmingly, cyberattacks.”
The time for action is now. Sakka points out that half of OT-targeted attacks “aim to seize physical control of industrial equipment, posing a direct threat to safety and operations.” Unfortunately, significant roadblocks remain in the way of effective OT-IT collaboration.
Sakka characterizes the situation as a classic “Catch-22,” noting that OT teams “fear that an embrace of IT will present new vulnerabilities. As OT systems become more interconnected, there are more ways for cybercriminals to get in or attack them. On the flip side, sticking to outdated legacy systems lacking modern security features also paves the way for cyberattacks.”
The way forward is “close collaboration” between OT and IT. According to Sakka, “[e]ducation is paramount. Encouraging collaboration and teamwork will enable a deeper understanding of factory-level challenges and needs. Creating opportunities for IT and OT teams to learn each other’s languages, understand each other’s priorities, and appreciate the interconnectedness of their roles is crucial.”
Effective cybersecurity implementation may require manufacturers to add more technology experts to their teams. Personnel with hands-on experience with advanced automation technologies used in manufacturing will play a key role in helping bridge the OT-IT divide.
It’s critical for manufacturers to hire highly skilled workers that can manage cybersecurity risks, in addition to operating, maintaining, troubleshooting, and repairing the advanced automation systems that are being implemented. Unfortunately, due to the ongoing “skills gap” issue in the manufacturing sector, finding highly skilled workers remains a significant challenge.
How can manufacturers find the workers they need? And how can they be sure that workers have the hands-on skills they need to succeed in the modern workplace? Today, more and more manufacturers are looking for workers with industry-standard certifications that prove they have the skills employers need.
For example, if workers possess a certification from the Smart Automation Certification Alliance (SACA), employers can feel confident they’ve already proven they have the knowledge and hands-on skills needed for working with advanced smart automation technologies. SACA has been hard at work collaborating with industry leaders to develop a wide variety of industry-standard certifications that will help employers find workers who possess the advanced connected-systems skills they need to take their businesses to the next level. Be sure to check out SACA and all it has to offer!
- Published in News
SACA Releases New Micro-Credentials
The Smart Automation Certification Alliance (SACA) is pleased to announce the release of new micro-credentials covering a variety of smart automation technologies into pilot phase. SACA members are encouraged to begin offering these credentials to ensure the workforce is certified in these essential areas:
- C-217 Smart Manufacturing Fundamentals
Prepares individuals to describe the principles, technologies, and applications of Smart Manufacturing, Industry 4.0, and the Industrial Internet of Things (IIoT) and how they affect the competitive position of manufacturers. Further, individuals must be able to safely operate basic smart automation systems that use Human Machine Interface (HMI) panels, monitor system operation parameters and energy usage using HMI visualization software, and connect/test to smart devices through point-to-point Ethernet communications.
- C-218 Smart Manufacturing Data Acquisition
Prepares individuals to identify types of manufacturing data and its function, describe how smart manufacturing data is collected and stored, set up and operate a dedicated cloud-based data acquisition system, interface and test analog and discrete sensing devices, configure and test wired and wireless Ethernet communications to sensors, and view data stored in a dedicated data acquisition system.
- C-219 Smart Manufacturing Visualization and Data Analytics
Prepares individuals to organize and interpret data using a variety of visualization methods, set up and operate visualization displays using dedicated and controller-based data acquisition systems, set up programmable controllers to collect data, configure Bluetooth technology to transfer information between devices, use OPC server software to facilitate data exchange between a smart device and a database or another smart device, set up Excel Spreadsheet, and use Excel to analyze data.
- C-220 Smart Manufacturing Data Transmission and Cybersecurity
Prepares individuals to assess potential cyber security threats to an industrial smart manufacturing system and data transmission methods, use best practices to protect stored and transmitted data against cyber security attacks, respond effectively to cyber security attacks, and set up secure industrial local area networks and firewalls.
- C-305 Industrial Electronic Systems 1
Prepares individuals to connect, adjust, operate, and troubleshoot industrial electronic linear DC power supplies, discrete input devices, and analog input devices. Troubleshooting skills include: adhering to electronic troubleshooting safety rules, reading electronic circuit diagrams, systems troubleshooting, component testing, and using digital multimeters, oscilloscopes, and status indicators. Components include: diodes, rectification circuits, Wheatstone bridge circuits, filter circuits, regulators, BJT transistors, PNP and NPN relays, analog temperature sensors, analog pressure sensors, analog proximity sensors, and signal conditioner circuits.
- C-306 Industrial Electronic Systems 2
Prepares individuals to connect, adjust, operate, and troubleshoot industrial electronic switching circuits used for motor control, switching power supplies and heating. Troubleshooting skills include: systems troubleshooting, component testing, and using digital multimeters, oscilloscopes, and status indicators. Components: FET/JFET/MOSFET/IGBT transistors, PWM amplifiers, switching DC power supplies, variable frequency amplifier circuits, operational amplifiers, SCR DC motor control switching circuits, and TRIAC AC motor control and heating switching circuits.
- C-307 Electronic Systems Installation 1
Prepares individuals to install and test/commission industrial electrical control systems that incorporate programmable logic controllers (PLC), human machine interface (HMI) panels, and variable frequency AC drives (VFD). Key skills include: adhering to electronic installation safety rules, using proper PPE, reading wiring installation diagrams with PLCs/HMIs/VFDs; cabinet mounting PLCs/HMIs/VFDs, wire routing and grounding PLCs/HMIs/VFDs, soldering/de-soldering to component terminals and printed circuit boards, installing Modbus and Ethernet communications network, and installing analog input transmitters and analog sensors.
- C-308 Variable Frequency Drive Systems 2
Prepares individuals to connect, configure, adjust, operate, and troubleshoot advanced AC variable frequency motor drives using sensorless vector and flux vector control modes. Key skills include: configuring control mode, connecting a VFD with 3-phase input, wiring/testing a dual channel incremental encoder interface and troubleshooting, configuring external speed control, monitoring and configuring PC-based drive software, configuring USB and Ethernet communications, and configuring/programming VFD communications with programmable logic controller.
- C-309 Programmable Controller Systems 2
Prepares individuals to program, configure, monitor, operate, and troubleshoot Ethernet communications between intelligent industrial automation devices using wired and wireless Ethernet communications. Key skills include: PLC implicit and explicit messaging, PLC distributed I/O, VFD-PLC Ethernet communications, VLAN security, wireless Ethernet networks, and IACS network troubleshooting.
- C-310 Ethernet Communications 2
Prepares individuals to program, configure, monitor, operate, and troubleshoot Ethernet communications between intelligent industrial automation devices using wired and wireless Ethernet communications. Key skills include: PLC implicit and explicit messaging, PLC distributed I/O, VFD-PLC Ethernet communications, VLAN security, wireless Ethernet networks, and IACS network troubleshooting.
- C-311 Data Analytics 1
Prepares individuals to program, configure, monitor, and operate cloud-based data analytics and Supervisory Control and Data Acquisition (SCADA) software systems in an Industry 4.0 environment. Key skills include: configuring production statistics collection from PLCs and other controllers via Ethernet networks, configuring production statistics and alarm dashboard display, OPC server configuration/interfacing to control devices, configuring maintenance management application, configuring alarm screen, configuring SQL database for storage of data from SCADA software, developing queries to SQL database to display data, and analyzing data to optimize systems.
- C-312 Robot Systems Integration 2
Prepares individuals to program, interface, and troubleshoot industrial robot systems in an Industry 4.0 automation environment. Key skills include: interfacing analog I/O to robot, communicating I/O control data to/from a PLC via Ethernet/IP network, vision guidance, and vision inspection. Programs commands include: group I/O, position offset, position register, analog I/O, Ethernet handshaking, end-effector macro, robot system troubleshooting, and alarm screen interpretation.
Smart automation technologies are vital parts of many major industries. These industries need highly skilled workers to fill thousands of open positions, and employers need to know that potential employees have the skills they need to hit the ground running.
That’s why SACA’s new micro-credentials were developed with input and guidance from a combination of industry experts and representatives from a variety of educational organizations. Thanks to these organizations and their expertise on the skills and competencies needed for today’s smart manufacturing workforce, SACA was able to create these new nationally recognized, occupation-driven micro-credentials.
About SACA
SACA sits at the forefront of the effort to certify students and workers who demonstrate the required knowledge and hands-on smart automation skills employers so desperately need. SACA’s certifications were developed in conjunction with industry partners who could speak from experience about their needs when it comes to workers able to work alongside a variety of advanced automation technologies.
SACA offers a wide variety of certifications in popular industrial skill areas, including certifications at the Associate, Specialist, and Professional level. For those wishing to focus on building a strong foundation of skills employers need, SACA also offers many micro-credentials that allow students and workers to add certifications as they master new areas.
For workers, SACA certifications can help market their smart automation skills to potential employers. For those employers, SACA certifications represent confirmation that a worker has the skills to hit the ground running in the workplace. To learn more about Industry 4.0 certifications and how SACA can help both future workers and industrial employers begin the task of bridging the Industry 4.0 skills gap, contact SACA for more information.
- Published in News
In a Pickle: AI Increases Production Efficiency at Kraft Heinz
In the year 2025, most people have at least a general understanding of the role advanced automation technology plays in their lives, including jobs that used to predominantly involve manual labor. For example, people walking into a modern automobile manufacturing facility would not be surprised to see rows of robots welding vehicle frames together.
Most people would also expect to find advanced automation technologies in facilities manufacturing high-tech products like semiconductors and electric vehicle batteries. But what about condiments? Does the automation technology revolution extend to industries like food and beverage?
The answer to that question is a resounding yes! According to a Food Dive article by Christopher Doering, “Kraft Heinz is using artificial intelligence to produce a better Claussen pickle.” So, the next time you ask for extra pickles on that burger, realize that artificial intelligence (AI) might have played a role in producing what you’re eating.
Those who have made pickles at home know that the basic process of making a pickle looks something like cucumber plus brine plus time equals pickle. While that may be easy enough in your home kitchen, doing so at scale can be quite a challenge.
For example, Doering notes that “Kraft Heinz processes approximately 60 million cucumbers annually to make roughly 42 million jars of Claussen, the country’s top-selling refrigerated pickle brand.” That’s a lot of pickles. Indeed, “[t]he cucumbers that turn into Claussen pickles move from vine to brine in 10 days or fewer, giving Kraft Heinz little room for error.”
What’s the big dill? (Pun totally intended.) According to Doering, “It’s paramount that Kraft Heinz knows what the cucumbers coming into the Claussen plant in Illinois look like so it can prepare — varying circumferences, lengths and bends can wreak havoc on planning and require changes to the production line where the spears are processed.”
Bill Durbin, the head of North America logistics and planning at Kraft Heinz, explains: “With pickles, the circumference matters, the size matters, the length matters, the bend of the cucumber, all of those things, depending on what they are, we will operate differently within the site, as well as quality.”
Durbin claims that “it’s super important that we identify issues as fast as possible and then make sure that we get the sizing correct so we can get the best efficiency as we run those things down the line. This allows us to get the best quality cucumber and the best quality pickles at the end.”
Kraft Heinz now uses AI and machine learning to automate the once-manual process of identifying issues in its cucumber supply. Durbin notes that “by having that level of certainty on what that product is, we can address that right away so we know where to send it within the factory, or if it’s an issue, we can get that real-time feedback to the suppliers to be able to address.”
And the result for Kraft Heinz? According to Durbin, “[o]n pickles, specifically, we’ve seen, since we put this in place, we’ve seen a 12% increase in efficiency from that. By being able to make this process and identify these things, we’ve been able to make sure that the pickles are getting routed to the right place to give us the best efficiency possible, and also to give that feedback to the suppliers.”
Given these impressive results, Durbin notes that Kraft Heinz is considering utilizing AI and machine learning in a similar way with other foods they process, such as tomatoes and potatoes. Perhaps one day your French fries will have been made more efficiently thanks to AI.
Of course, implementing new advanced automation technologies isn’t without its challenges. For example, many manufacturers already can’t find enough workers to fill open positions. Where are they going to find the highly skilled workers to take advantage of these new technologies?
The solution, of course, is to either upskill current workers or hire new workers with the advanced automation technology skills they require. How can manufacturers be certain prospective workers have the skills they need?
Manufacturers should look for candidates with industry-standard credentials that prove they already possess the skills they need to thrive. For example, if workers possess a certification from the Smart Automation Certification Alliance (SACA), employers can feel confident they’ve already proven they have the knowledge and hands-on skills needed for working with advanced smart automation technologies. SACA has been hard at work collaborating with industry leaders to develop a wide variety of industry-standard certifications that will help employers find workers who possess the advanced connected-systems skills they need to take their businesses to the next level. Be sure to check out SACA and all it has to offer!
- Published in News
