The Hierarchy of Industrial Automation Systems

Industrial automation is a process of using advanced technologies and control systems to automate industrial operations, resulting in increased efficiency, consistency in products, productivity, and safety.?

The hierarchy of industrial automation refers to the different levels of control and management involved in the automation process. These levels are organized with each layer having its specific roles. Here are the typical levels of industrial automation hierarchy:

Level 0: Process Control:

This is the lowest level of the hierarchy and involves direct control of the physical processes and equipment. It includes sensors, actuators, switches, and other field devices that interact directly with the manufacturing process. These devices collect data and provide real-time feedback to the control system.

Level 1: Basic Control:

At this level, basic control functions are performed by local controllers, the most popular device used here being the Programmable Logic Controllers (PLCs). They use processed sensor signals and control techniques to drive the actuators. These controllers handle simple control loops and regulate individual machines or processes. Examples include PID (Proportional-Integral-Derivative) controllers that maintain specific variables like temperature, pressure, or flow rate within predefined setpoints.

Level 2: Supervisory Control:

The supervisory control level is responsible for overseeing multiple basic control loops and coordinating their activities. It includes supervisory control systems like SCADA (Supervisory Control and Data Acquisition) and DCS (Distribution Control Systems) plus HMI (Human-Machine Interface) software that allow operators to monitor the overall process, make adjustments, and respond to alarms or abnormal conditions.?

Level 3: Manufacturing Execution System (MES):

MES is a higher-level system that integrates production planning, scheduling, and resource allocation. It bridges the gap between the supervisory control level and the business planning level. MES monitors and manages production processes in real-time, collects data, and provides detailed production reports. We can set production targets at this level.

Level 4: Enterprise Resource Planning (ERP):

The ERP level is the highest level in the industrial automation hierarchy. It focuses on the overall business management and coordination aspects, including supply chain management, production planning, customer/market analysis, finance, human resources, and sales. Data from lower levels of automation is integrated into the ERP system to provide a comprehensive view of the entire organization's operations.

It's important to note that in some industries and systems, there may be additional levels or variations in the hierarchy to cater to specific requirements. Additionally, with the advancements in technologies like IIoT (Industrial Internet of Things) and AI (Artificial Intelligence), new paradigms are emerging in industrial automation, leading to even more sophisticated and interconnected systems. These evolving technologies continue to reshape the industrial automation landscape, driving innovation and efficiency across various industries.