Bridging the IT-OT Divide in Manufacturing with John Rinaldi of Real Time Automation
What happens when a toy industry dreamer pivots into industrial communication and becomes one of the most respected minds in manufacturing networking? You get John Rinaldi—founder of Real Time Automation and one of the most practical, no-BS thinkers on the challenges and future of Industry 4.0. We sat down with John on the Manufacturing Runs The World podcast to unpack the very real struggles manufacturers face when trying to modernize their operations. Spoiler: it’s not just about technology—it’s about people, systems, and old machines that just won’t die.
From Toys to PLCs
Back in the 1980s, John set out to build toys. But demand pulled him toward industrial automation instead—and the world’s been better for it. Today, Real Time Automation helps manufacturers integrate their legacy equipment into modern networks with ease. He's written eight books, developed products like the "Interview" diagnostic tool, and built a team of 27 experts tackling real-world factory challenges—especially around industrial networking.
Why Industry 4.0 Isn’t a Plug-and-Play Dream
“97% of manufacturers in the U.S. have under 200 people,” John reminds us. Most of them don’t have IT teams ready to build a modern, secure, scalable data infrastructure. The challenge? Legacy systems, unmanaged switches, undocumented firmware levels—and a huge knowledge gap between IT and OT (Operational Technology). John’s take is refreshingly blunt: "People don’t understand the difference between a manufacturing network and an IT network. One’s a system of systems. The other is just computers."
When Netflix Kills the Stamping Machine
One of our favorite stories from the episode: A stamping machine mysteriously started running slow. The culprit? Someone was streaming Netflix—over the same unmanaged switch running the machine. If that doesn’t scream “You need network management,” we don’t know what does.
Proactive Maintenance, Not Firefighting
With tools like RTA’s “IntraVUE,” manufacturers can map their network topology, monitor firmware levels, and fix problems before they cause downtime. It’s all about visibility and predictability—two things most plant floors lack. John’s mission is clear: eliminate the guesswork, prevent disasters, and empower control engineers with tools that actually make sense.
Why This Matters for Small Manufacturers
Industry 4.0 sounds cool in theory, but as John puts it: “It’s not a technology problem—it’s a people problem.” Without the right people, training, and tools in place, even the best tech won’t move the needle. That’s why Real Time Automation focuses on simple, reliable, and cost-effective solutions tailored to small and mid-sized manufacturers.
Key Takeaways
- Don't overthink Industry 4.0. Start with visibility—know what’s on your network.
- Legacy machines can stay—if you know how to integrate them.
- Most downtime is preventable. It just takes better diagnostics and documentation.
- Cybersecurity isn’t optional. Especially with unmanaged devices and open networks.
- Tools like “IntraVUE” give you clarity on what’s working—and what’s about to break.
