Salas O’Brien experts Bryan Cousino, John Glenski, Todd Plymale, and Julie Hoffherr explain how digital twins transform plant floors for better quality, compliance, ROI, and resilience.

Why this matters now

Manufacturers are investing in connectivity, analytics, and automation in pursuit of better quality, higher throughput, and more responsive operations. The promise is real, but so are the challenges. Plant teams are working through legacy systems, skill gaps, data silos, and the question of where to start. Digital transformation that delivers value looks different from the conference room slides. It is grounded in specific use cases that pay for themselves.

What leaders are weighing

Operations leaders are weighing the appeal of broad digital strategies against the value of targeted projects with clear paybacks. They are deciding how to integrate operational technology with information technology without overwhelming the people who run the plant. There are tradeoffs around platforms, cybersecurity, vendor relationships, and how to build internal capability. Finance teams want defensible business cases. Plant teams want tools they will actually use. The right approach combines vision with disciplined sequencing.

How Salas O’Brien is helping clients respond

Our manufacturing and automation teams help clients translate digital ambitions into projects that pay back. We bring controls, automation, IT/OT integration, and process expertise together with experience working alongside plant leadership. We help clients identify use cases, sequence investment, and engage operators and engineers so transformation actually changes how the plant runs. Hear Bryan Cousino, John Glenski, Todd Plymale, and Julie Hoffherr talk about what digital transformation looks like on the plant floor.

Contributors
Bryan Cousino PE, MBA

Bryan Cousino PE, MBA

Bryan Cousino, PE, MBA brings a business-led approach to complex engineering challenges, helping clients turn unclear paths into practical solutions. He works across industrial, food and beverage, pharmaceutical, lab science, and mission-critical sectors, aligning teams and applying business insight to technical decisions. Bryan serves as a principal at Salas O’Brien. Contact him at [email protected].

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John Glenski, CPM

John Glenski, CPM

John Glenski is a leader in digital transformation in the industrial sector with a demonstrated history of providing data-driven outcomes for the world’s largest manufacturers. John works collaboratively with internal and external partners to deliver innovative solutions for smart manufacturing (automation, material handling, and data/information solutions) with a focus on sustainable applications. John serves as a Principal & Senior Director of Automation & Digital at Salas O’Brien. Contact him at [email protected].

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Todd Plymale

Todd Plymale

Todd Plymale is a leader in business development and automation. He brings sales, operations, engineering, and product together to set strategy, build pipelines, and lead multi-site programs across healthcare, consumer goods, and industrial markets. Over the past twenty-five years, he has led 500+ automation projects, built and coached teams, refined estimating and delivery standards, and deepened executive relationships that sustain long-term partnerships. Todd serves as a Vice President at Salas O’Brien. Contact him at [email protected]

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Julie Hoffherr, MBA, MIM

Julie Hoffherr, MBA, MIM

Julie Hoffherr is an experienced automation lead with twenty-one years in industrial automation and controls, gaining the trust of clients in automotive, pharmaceutical, metal, chemical, and utility markets. Her responsibilities span project management, PLC programming, HMI application development, system installations, I/O checkout, commissioning, validation, and site support. Julie serves as a Vice President at Salas O’Brien. Contact her at [email protected]

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