Understanding the Automation Pyramid From Enterprise to Device Level

Automation transforms operations, making processes and production faster, more efficient, and more precise. Automation systems are applied at different levels, each with a specific role in ensuring the operation runs smoothly.

Automation operates at five levels: Enterprise, Plant, System, Machine, and Device. Each level manages different functions, from company management to individual machine control, enhancing efficiency, precision, and production.

1. Enterprise Level

At the very top of the automation system is the Enterprise Level. This level is where the company’s management happens. It includes everything from marketing, sales, and research to production planning and scheduling. Enterprise Resource Planning (ERP) systems are often used to manage information and help the company make decisions about production, sales, and other important areas.

Key Responsibilities:

- Managing company-wide activities like sales, accounting, and production planning.

- Using ERP systems to make decisions that affect the entire system.

2. Plant Level

The Plant Level focuses on the entire production system. It receives instructions from the enterprise level and turns them into actions. This is where the production plans are made real through activities like order processing, inventory control, and quality control. The plant level ensures everything runs smoothly on the factory floor.

Key Responsibilities:

- Managing inventory and production orders.

- Ensuring quality control and efficient production processes.

3. Cell or System Level

The Cell or System Level operates with groups of machines or workstations working together. These machines are connected through computers and material handling systems. This level focuses on ensuring different machines work together efficiently, handling tasks like loading machines, coordinating work, and collecting data on production quality.

Key Responsibilities:

- Machines and workstations are connected and coordinated.

- Tasks like machine loading and data collection are managed.

4. Machine Level

At the Machine Level, individual machines like CNC machines or industrial robots are controlled. The machines receive instructions and follow them step by step to perform tasks. This level ensures that machines like conveyors or robots operate in the correct order and without mistakes.

Key Responsibilities:

- Controlling individual machines like CNC machines or industrial robots.

- Ensuring tasks are done correctly in the right order.

5. Device Level

Finally, at the base of the system is the Device Level. This is where the basic hardware components like sensors, actuators, and controllers are found. These devices are responsible for controlling the finer movements of machines, such as moving the joint of a robot or controlling the speed of a conveyor belt. It’s the foundation of the entire automation process.

Key Responsibilities:

- Sensors and actuators control the basic functions of machines.

- The smallest details, like the movement of robot parts, are handled.

Conclusion

Automation operates at five levels, each with a specific role, from managing the company at the enterprise level to controlling individual machines at the device level. These levels work together to make factories more efficient, accurate, and productive. Understanding how each level functions can help companies optimize their production and achieve better results in the long run.