Mark Collins is a senior engineer at Mazak with a bachelor of science degree in electro-mechanical engineering from Miami University. With more than 25 years of experience in a variety of roles in the manufacturing and machine tool industry, Collins has acquired a breadth of experience in robotic automation, machining process, industrial networking and security. He is looking forward to seeing how artificial intelligence, big data and the continued move toward a more connected manufacturing industry will affect the future of manufacturing.
What is the primary focus of software-defined automation (SDA)?
Mark Collins, senior engineer, Mazak: Software-defined automation (SDA) is a concept that continues to evolve, but, at its core, the primary focus of SDA is to decouple automation logic from hardware, allowing software to define, control and manage automation processes. This means that instead of being locked into rigid, hardware-centric configurations, manufacturing systems can be rapidly reconfigured, customized and optimized through software. The term "define" is crucial here because it highlights how SDA enables software to manage not only control, but also the setup, configuration and initialization of automation systems.
What are the primary benefits of software-defined automation?
Mark Collins, senior engineer, Mazak: Software-defined automation’s primary benefit is time savings. In modern manufacturing, whether it is downtime, changeovers or engineering hours, the pressure is constant: deliver more, do it faster and achieve better results with fewer resources. The potential for SDA to significantly reduce the required engineering efforts to design, reconfigure and/or scale your manufacturing process can be impressive. Companies that fail to integrate SDA may find themselves with longer delays switching production lines and implementing the changes that our customers demand of all of us.
How does software-defined automation figure in the convergence of IT and OT?
Mark Collins, senior engineer, Mazak: Software-defined automation is a critical enabler of the ongoing convergence between information technology (IT) and operational technology (OT) in manufacturing environments. Traditionally, IT, focused on data processing, networking and security, and OT, focused on direct control of machinery and industrial processes, operated in silos. SDA breaks down this divide by making automation processes software-driven, allowing seamless communication and data exchange between the two domains. SDA allows IT systems, such as enterprise resource planning (ERP) or manufacturing execution systems (MES) to directly access real-time data from shop floor equipment. This means that production data, machine status and maintenance information can be instantly shared with IT systems for analysis, optimization and decision-making.
SDA also brings DevOps practices into the industrial environment. Traditionally, DevOps has been a set of practices, tools and a cultural philosophy aimed at automating and integrating processes between software developers and IT teams. In SDA, this philosophy will extend to OT. Software developers will work alongside OT engineers to create, test and deploy automation applications that will be the building blocks for the software-defined system.
Which standards and protocols will be affected most or increase/decrease in use because of software-defined automation?
Mark Collins, senior engineer, Mazak: Portability and interoperability are key to SDA. Open protocols such as OPC UA, which facilitate secure and reliable data exchange across different platforms, and message queuing telemetry transport (MQTT), which supports lightweight, publish/subscribe messaging, are ideal for SDA applications. Also, domain-specific semantic vocabulary standards like MTConnect will provide clear, consistent data. Real-time communication protocols like EtherNet/IP, Profinet and others will continue to provide time-sensitive communication.
The mandatory requirements of interoperability in SDA, along with a growing library of code, will diminish vendor-specific protocols. The rise of SDA and the growing library of open-source software and industry standards will diminish the dominance of proprietary, vendor-specific protocols. Companies that rely solely on closed, vendor-specific solutions will struggle to achieve the flexibility and scalability that SDA offers.
Which components will see the biggest impact from software-defined automation?
Mark Collins, senior engineer, Mazak: Software-defined Automation will have a transformative impact on a wide range of industrial components, but the most significant changes will occur at both ends of the automation spectrum — the largest control systems and the smallest sensing devices. Traditionally, industrial control systems like programmable logic controllers (PLCs), programmable automation controllers (PACs), and industrial PCs (IPCs) have been hardware-centric, with dedicated devices handling control logic. However, SDA is pushing these control functions into the cloud or distributing them across multiple software layers. This means that, instead of a single, fixed controller managing a process, control logic can be dynamically assigned, scaled and managed through virtualized software environments.
At the opposite end, even the smallest components like sensors are undergoing a transformation. Traditional sensors were simple devices that fed raw data to controllers and up the line of distributed control systems, but, with SDA, sensors are becoming intelligent, capable of processing data locally and communicating directly with multiple higher-level software platforms. A temperature sensor can now have built-in processing power, filtering and analyzing data locally before sending it directly to a cloud dashboard; and sensors that support open protocols like OPC UA or MQTT can seamlessly connect to SDA systems without needing intermediate control devices.
In what ways does software-defined automation allow machine builders more flexibility in hardware selection and management?
Mark Collins, senior engineer, Mazak: Properly configured SDA systems will give machine builders greater freedom in choosing and managing hardware components. The ability to select hardware from different vendors without compatibility issues will help with scalability and customization without needing to overhaul the entire manufacturing system.
A machine builder can integrate a new sensor from a different manufacturer into an existing system without significant reprogramming, thanks to SDA. The decoupled control of individual pieces of hardware will allow for quick deployment into new or updated manufacturing systems.
How can machine builders prepare for and leverage software-defined automation?
Mark Collins, senior engineer, Mazak: Adopting SDA requires careful strategic planning. One of its biggest challenges is the tendency to overextend its scope — trying to be all things to all people. As original equipment manufacturers (OEMs) start implementing their SDA, they can do so by defining the core business. OEMs will need to develop the pieces specific to their systems and build relationships with partners that can provide components that should seamlessly integrate with their systems.
How does software-defined automation build on existing IT and network infrastructure in factories and plants?
Mark Collins, senior engineer, Mazak: Software-defined automation should be designed to leverage existing IT network infrastructure within factories, minimizing the need for extensive hardware upgrades. Integrating SDA with ERP and MES enables real-time monitoring and control of production processes without major changes to the infrastructure. While many Internet of Things (IoT) devices can generate a large amount of data, a properly developed SDA solution can introduce intelligent edge devices that function as local data processors. These edge devices filter and process high-frequency data pushing only critical or processed information to higher network layers. This approach reduces network load, and it prevents network congestion, while also enhancing security since sensitive data can be processed locally without unnecessary exposure to the network.
Tell us about your company’s state-of-the-art product that involves software-defined automation.
Mark Collins, senior engineer, Mazak: Mazak has a long history of pioneering software-driven automation, starting in 1981 with the introduction of Mazatrol, one of the world's first conversational CNC controls. This innovation allowed operators to program CNC machines using user-friendly, graphical commands rather than complex G-code, significantly enhancing efficiency on the shop floor. In 1998, Mazak continued to lead by integrating PC technology directly into our CNC controls with the launch of the Fusion CNC, bringing advanced computing capabilities to the manufacturing floor.
Today, Mazak remains at the forefront of software-defined automation (SDA) with our industry-leading SmoothAi control. SDA refers to the concept where automation logic, monitoring and management are driven primarily by software, rather than being hard-coded into hardware. This approach provides unmatched flexibility, enabling rapid adjustments to machining parameters, seamless integration with other factory systems and remote monitoring capabilities.
Mazaks SmoothAi control exemplifies this philosophy. Mazatrol SmoothAi is an intuitive, software-driven programming interface that accelerates setup and programming. Smooth Project Manager is a centralized software solution for managing machining programs and configurations. Smooth CamAi is an advanced CAD/CAM integration for rapid part programming. Digital twin integration enables operators to simulate and optimize machining operations virtually before execution.
By providing a platform that can adapt through software updates, integrate seamlessly with IoT devices and leverage advanced data analytics, Mazak's SmoothAi control empowers manufacturers to achieve greater flexibility, efficiency and scalability.
As industry increasingly moves toward a software-centric manufacturing environment, companies that rely on rigid, hardware-dependent systems will find themselves struggling to adapt. Mazak’s commitment to software-defined automation ensures our customers remain competitive in a rapidly evolving landscape.
