A useful approach for developing a successful automation strategy is provided by the so-called automation pyramid, which can be used to depict the general communication structure of automated production.
What is the automation pyramid?
The automation pyramid is used to classify techniques and systems in control technology and to represent the different levels within industrial production. Its structure can vary from company to company. There are more than 25 versions in the literature, which differ in the number and naming of the levels.
Which levels does the automation pyramid comprise?
In most cases, the pyramid is divided into five or six levels. The base (level 0) is the process level with sensors and actuators that supply data and execute commands. At Demig, we combine this level 0 with level 1. The levels are therefore:
Level 1 - Field or process level: Collects data, usually from sensors, and sends it to actuators.
Level 2 - Control level: Controls the production process by evaluating sensor data and issuing commands (e.g. PLC controller)
Level 3 - Process control level: Monitoring and operating, recipe management via the process management system (e.g. SCADA),
Level 4 - Plant management level: detailed production planning, quality management, data acquisition, material management, KPI acquisition (e.g. MES)
Level 5 - ERP (production planning, order processing)
Sometimes the ERP level and the plant management level are combined to form the management level. In some cases, levels 0 and/or 5 are omitted because they are not needed.
How can companies benefit from implementing the automation pyramid?
The pyramid is an important element for planning and visualizing automation projects in industry. It builds a bridge between a company's technical processes and the business processes above them and describes the path of data from production to ERP. This makes it possible to compare planned performance with actual performance at any time - an important step towards a transparent factory. Likewise, products, orders and programs, and possibly even materials, can be assigned to specific machines and systems and sent to them.
What challenges arise when implementing the automation pyramid and how can they be overcome?
Many systems in the company that are involved in the pyramid have grown historically. As a result, it is not always possible to pass data through without interference or loss. Media discontinuities play a role here, as does a non-uniform architecture.
In addition, the systems that map the automation pyramid are relatively sluggish. The more data that moves toward the top, the tighter the traffic and the stronger the decision-making processes become.