A new era for industry collaboration
October 2025 marked a pivotal moment for the South African automation and manufacturing community, as the SAIMC User Advisory Council hosted its first annual summit under the SAIMC banner. Formerly known as the MESA Africa Annual Conference, this rebranded event signalled a broader, more inclusive approach to industry challenges and opportunities. The summit drew over 100 registered delegates, its largest attendance in 15 years, reflecting the growing appetite for knowledge sharing and collaboration in a rapidly evolving sector.
The summit’s agenda was ambitious: spanning plant and business automation, artificial intelligence, sustainability, workforce development and the intersection of technology with human factors. The event featured a diverse lineup of local and international speakers, thought leaders, economists and practitioners, as well as interactive panel discussions. The atmosphere was energetic and forward-looking, with a clear focus on practical solutions and strategic foresight.
Day one: Technology, people and process
Andy Sherring: Don’t digitise your rubbish
Andy’s keynote set the tone for the summit, challenging delegates to rethink digital transformation. He cautioned against the uncritical adoption of new technologies, noting that the pace of technological advancement often outstrips an organisation’s ability to absorb and leverage these tools effectively. Sherring highlighted a global trend: productivity is declining as experienced baby boomers retire and staff turnover rises. New employees frequently move on before mastering core processes, undermining organisational stability.
Andy’s central message was that true improvement must be systemic and sustainable, lasting beyond the tenure of consultants or project teams. He advocated for the systemisation of data capture, transparency and visualisation, enabling effective decision making aligned with organisational strategy. He warned that misaligned objectives and poor information can lead to decisions that are detrimental to business outcomes. His insights resonated with delegates grappling with the realities of digital transformation in complex, resource-constrained environments.
Dagan le Roux: Mining 4.0 − Bridging the gap between digital intention and execution
Dagan’s presentation focused on the human dimension of digital transformation, particularly in the mining sector. He argued that insufficient attention is paid to people’s involvement in change initiatives, and that successful transformation hinges on robust change management. He emphasised that each project is unique and requires a tailored approach. Key recommendations included appointing a local champion, co-designing solutions with end users, demonstrating value through practical examples, implementing changes gradually, and maintaining transparent communication throughout the project lifecycle.
Dagan’s approach underscored the importance of empathy, engagement and adaptability in driving successful digital interventions. His practical advice, rooted in real-world experience, provided a valuable roadmap for organisations seeking to bridge the gap between digital ambition and operational reality.
Bernard Meister: Hidden factories
Bernard’s talk on hidden factories shed light on the often-overlooked costs of poor automation and process control. He explained how inadequate control systems can lead to increased material and energy waste, accelerated equipment wear and tear, and heightened risk of environmental and safety incidents. Meister argued that improving process control can unlock significant hidden value, revealing efficiencies and capabilities that were previously invisible.
A key takeaway was the need for cross-disciplinary collaboration in control system design, ensuring that all perspectives are considered. Meister identified information lag and dead-time as the primary enemies of effective control – both in manufacturing and in business decision-making. The delay between data generation, analysis and action can have substantial financial and operational consequences, reinforcing the need for real-time information and agile execution.
Hein Smit: Business needs to work smart
Hein’s presentation focused on the transformative potential of automating routine administrative tasks. By streamlining approvals and accelerating access to decision-making information, organisations can achieve significant business benefits. Smit stressed that technology alone is not enough; employees must also be equipped with the right mindset to embrace and maximise the value of automation. His message was clear: smart business is about empowering people to work more efficiently and make better decisions, not just about deploying new tools.
Luigi de Bernadini: Where MES meets AI
International speaker, Luigi de Bernadini delivered a compelling analysis of the intersection between manufacturing execution systems (MES) and artificial intelligence. He described a world in flux. Supply chains are more volatile than ever, customers demand greater customisation and regulatory pressures are mounting. Compounding these challenges is a global workforce shortage, as experienced employees retire and younger workers seek rapid career progression.
Luigi argued that MES provides the essential data foundation for successful AI initiatives in manufacturing. He shared case studies demonstrating that AI applications, such as predictive maintenance, anomaly detection, dynamic scheduling, operator assistance and automated reporting, can deliver substantial benefits, including higher throughput, reduced waste, improved sustainability and empowered operators. However, he cautioned that effective AI deployment requires careful planning, robust data infrastructure and ongoing evaluation.
His vision of a ’golden day’ in manufacturing, where proactive, AI-guided decisions replace firefighting and production objectives, are met despite disruptions, captured the imagination of delegates and set a high bar for industry ambition.
Day two: Strategy, sustainability and skills
Chris Hatting: Navigating the new global trade landscape
Chris opened the second day with a strategic overview of global trade dynamics. He noted that elevated uncertainty and geopolitical tension are now permanent features of the landscape. Trade is increasingly integrated and transactional, with alliances shifting and non-trade factors, such as ideology, influencing deals. For South Africa and the broader African continent, Hatting identified population growth and relatively low debt as key advantages, contrasting with the high debt burdens of the USA and EU.
Chris argued that South Africa’s competitiveness depends on its ability to compete globally, not on subsidies or protectionism. He outlined four plausible geopolitical scenarios for South African companies: alignment with China, alignment with the USA, failed alignment with both, or successful non-alignment (à la Switzerland). He urged companies to plan for all contingencies and to leverage their human resources and market potential to drive economic growth.
Christa Dowd: Data-driven sustainable energy management
Christa’s presentation tackled the urgent challenge of sustainable energy management. She argued that no single green energy source is perfect or universally reliable, making energy efficiency a critical priority. Dowd advocated for the integration, standardisation and validation of diverse data sources to provide real-time visibility for cross-functional teams. By leveraging data-driven insights, organisations can eliminate inefficiencies through effective load scheduling, correct equipment sizing, proactive maintenance and targeted resolution of operator errors and power quality incidents.
Christa’s closing remarks echoed a recurring theme of the summit: automation and decision-making are only as good as the quality and reliability of the underlying data. Trustworthy data is the foundation for sustainable, efficient operations.
Mechelle van der Vyver: A tale of two projects
Mechelle shared a compelling case study comparing two technology projects within the same steel industry group. One project took three years to complete, plagued by issues and inefficiencies, while the other was delivered in under three months with minimal problems. Both projects involved similar technologies and contexts, highlighting the decisive impact of project management practices.
Van der Vyver identified several critical success factors: early scope definition and buy-in, infrastructure readiness, clean and accurate master data, early user involvement, dedicated system testing away from daily operations, and strong plant-floor discipline. She cautioned that technology cannot compensate for underlying process or discipline issues; if a paper-based system fails due to poor discipline, a digital system will fare no better. Her insights underscored the importance of foundational practices in ensuring successful technology adoption.
Theodore Turner: MOM digital transformation
Theodore recounted his company’s journey through a manufacturing operations management (MOM) digital transformation. Specialising in the design and manufacture of agricultural machinery, Turner’s company faced the challenge of managing highly customised, engineering-driven production. The transformation focused on enhancing material and labour tracking, balancing workload and capacity, decentralising scheduling to team leads on the shop floor, and providing real-time performance visibility at workstations.
The results were striking. Real-time visibility enabled operators to adjust their behaviour, leading to measurable productivity gains. Turner’s experience demonstrated the power of digital tools to drive cultural and operational change, even in complex, high-mix manufacturing environments.
Yanesh Naidoo: Use case of AI on the shopfloor
Yanesh described his company’s evolution from a traditional machine builder to a software-driven innovator. With 90% of its production exported to major global markets, the company developed software to monitor production lines and guide operators using AI and computer vision. Applications included object classification, quality inspection (e.g., torque monitoring) and error detection.
Naidoo also showcased the use of large language models and natural language processing to enable verbal production, quality, and labour reporting. By harnessing big data and AI, the company improved quality, efficiency and operator guidance, illustrating the transformative potential of digital technologies on the shop floor.
Horst Weinert: Bridging the industry/education divide
Horst delivered a thought-provoking critique of the current state of industry-education collaboration. He argued that SETA funding is not being used effectively, resulting in graduates who are not immediately employable and require extensive retraining. With global skills shortages, these graduates often leave jobs before becoming valuable contributors.
Weinert called for academia to bring industry into the classroom, reducing the gap between education and employment. He advocated for measuring universities by post-graduate industry placements rather than pass rates or research output. Weinert also highlighted the decline in artisan training, noting that only 3,000 artisans are trained annually, compared to 30,000 in the 1990s. He challenged the perception that vocational education is inferior, emphasizing its role in wealth creation and entrepreneurship.
Terence Fogarty: Cybersecurity in operational technology: Hack the plant
Terence’s session on cybersecurity was both sobering and practical. He presented case studies of cyberattacks on operational technology (OT) environments, highlighting the severe consequences of breaches. Fogarty outlined a range of protective measures, including data loss prevention, security operations centres, privileged access management, security incident event management, zero trust network access and cloud access security brokers.
He explained that OT is increasingly targeted due to its critical infrastructure role, lack of real-time visibility and outdated security practices. The convergence of IT and OT systems introduces new vulnerabilities, while poor segmentation and monitoring allow attackers to move quickly once inside. Fogarty warned that most attacks exploit known vulnerabilities using freely available tools, underscoring the need for proactive, layered security strategies.
Niniza Mtshali: Identification of engineering work and ECSA registration
Niniza reinforced the importance of professional registration with the Engineering Council of South Africa (ECSA) for all individuals engaged in engineering work, including educators. Registration ensures accountability, professional standards and public trust in engineering practice.
Vinesh Maharaj: Turning disruption into sustainable innovation
Vinesh closed the summit with a forward-looking discussion on sustainability as a driver of innovation and competitiveness. He argued that sustainability practices are becoming essential for access to export markets, particularly in the EU and USA where net-zero manufacturing will soon be mandatory. He emphasised the need for circular economy thinking in product and packaging design, considering reuse, refurbishment and end-of-life management.
He also highlighted the significance of Scope 3 emissions, those outside a company’s direct control, which can account for up to 98% of total emissions in some sectors. Maharaj’s message was clear: organisations that embrace sustainability will be better positioned to thrive in a rapidly changing global landscape.
Panel discussions: Diverse perspectives, shared challenges
Gender-inclusive smart workforce
Facilitated by Raksha Naidoo, this panel addressed the persistent underrepresentation of women in mining and manufacturing. Panelists discussed cultural perceptions of these industries as ‘dirty’ or’ manly’, ongoing workplace discrimination and the importance of avoiding a victim mentality. The discussion emphasised the need for proactive strategies to attract, retain and empower women in technical roles, recognising diversity as a driver of innovation and resilience.
AI in manufacturing: People at the heart
Charl Marais led a panel on the transformative impact of AI in manufacturing. Panelists agreed that AI’s potential is often underestimated and that its adoption is an ‘adapt or die’ proposition. They stressed the importance of balancing technology, people and governance to ensure positive outcomes. The panel warned of the risk of bias in AI systems, particularly in recruitment, and called for vigilant oversight to ensure fairness and inclusivity.
AGOA: Springboard or stumbling block?
Gary Lane facilitated a discussion on the African Growth and Opportunity Act (AGOA) and its impact on South African manufacturing. The panel concluded that AGOA has not significantly enhanced South Africa’s global competitiveness and may have fostered complacency in some sectors. The discussion highlighted the need for broader, more strategic approaches to trade and industrial development.
Looking ahead
The 2025 SAIMC User Advisory Council Annual Summit was a resounding success, setting a new standard for industry engagement and thought leadership. The event highlighted the critical interplay between technology, people, data and sustainability in shaping the future of manufacturing and automation. Delegates left with practical insights, renewed connections and a shared commitment to driving innovation and excellence.
The SAIMC expressed its gratitude to sponsors, delegates and organisers, and invited all stakeholders to participate in the 2026 summit, scheduled for 14 to 15 October 2026. Early-bird registration details will be shared via social media and email.
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