What is the Automation Pyramid?

Summary

This video explains the Automation Pyramid, a model that illustrates different levels of automation in industry. Starting at the field level, which includes sensors and actuators on the production floor, it moves up to the control level with PLCs and PIDs managing these devices. The supervisory level introduces SCADA for overseeing multiple systems, followed by the planning level using MES to monitor the entire production process. At the top is the management level, where ERP systems provide company-wide oversight. The video emphasizes how integrated technology boosts efficiency and transparency in industrial automation.

Takeaways

• 🔧 The automation pyramid is a visual representation of different levels of automation in a factory or industry.
• 🏭 The field level at the bottom consists of devices like actuators and sensors found on the production floor.
• ⚙️ The control level, which includes PLCs (Programmable Logic Controllers) and PIDs, manages the devices at the field level.
• 🚗 A PID is commonly used for control systems, such as cruise control in cars or heaters in industrial plants.
• 🖥️ The supervisory level uses SCADA (Supervisory Control and Data Acquisition) to control and monitor multiple systems remotely, often with a graphical user interface (HMI).
• 🌊 SCADA technology is often used in water plants to manage remote systems like pumps from a single location.
• 📊 The planning level is managed by MES (Manufacturing Execution System), which tracks the entire production process from raw materials to the final product.
• 📈 The top level, called the management level, utilizes ERP (Enterprise Resource Planning), allowing company leaders to monitor and manage overall operations.
• 🧑‍💼 ERP integrates all levels of a business, promoting efficiency and transparency by unifying various company departments.
• 🎓 RealPars offers comprehensive training in automation and controls engineering, including PLC programming, which can lead to highly sought-after jobs.

Q & A

What is the automation pyramid?

The automation pyramid is a pictorial representation of the different levels of automation in a factory or industry. It shows how various technologies are integrated to manage and control industrial operations.

What devices are found at the 'field' level of the automation pyramid?

At the 'field' level, devices include actuators, sensors, electric motors, hydraulic and pneumatic actuators, proximity switches, and photoelectric switches. These devices perform the physical work and monitoring on the production floor.

What is the role of the control level in the automation pyramid?

The control level uses PLCs (Programmable Logic Controllers) and PIDs (Proportional–Integral–Derivative controllers) to control the devices at the field level. It processes information from sensors and other input devices to make decisions and manage outputs.

What is a PID, and how is it used in industrial automation?

A PID is a Proportional–Integral–Derivative controller that maintains variables within a set of parameters. In industrial automation, PIDs are used to control systems like heaters by adjusting outputs to maintain a desired setpoint, such as temperature.

How does SCADA fit into the automation pyramid?

SCADA (Supervisory Control and Data Acquisition) is used at the supervisory level of the automation pyramid. It monitors and controls multiple systems from a single location, often incorporating a graphical user interface (HMI) for remote control of operations.

What is the difference between SCADA and HMI?

HMI (Human-Machine Interface) typically controls a single machine or system, while SCADA can monitor and control multiple systems across larger areas from a centralized location.

What is the role of the MES (Manufacturing Execution System) in the automation pyramid?

MES operates at the planning level of the pyramid, monitoring the entire manufacturing process, from raw materials to finished products. It helps management make decisions based on real-time data from the factory floor.

What does the ERP system do at the top of the automation pyramid?

The ERP (Enterprise Resource Planning) system is used by top management to monitor and control the entire business operation. It integrates data from different levels of the pyramid, including manufacturing, sales, finance, and other functions, promoting efficiency and transparency.

Can SCADA systems control systems over long distances?

Yes, SCADA systems are designed to control and monitor operations over large areas and long distances, making them ideal for industries like water plants that require remote control of equipment.

How does the automation pyramid improve industrial operations?

The automation pyramid improves efficiency by integrating different technologies at various levels, from the production floor to enterprise management. It allows for centralized control, real-time monitoring, data-driven decision-making, and improved transparency across the organization.

Outlines

00:00

🔧 Understanding the Automation Pyramid

This introduction sets the stage for discussing the Automation Pyramid, a model representing different levels of automation in industrial settings. The host explains that the pyramid is a visual representation of how technology integrates into industry. The video will explore each level of the pyramid, starting from the 'field' level where sensors, actuators, and devices on the production floor perform physical tasks. The focus is on how the pyramid helps simplify understanding industrial automation.

05:03

⚙️ The Field and Control Levels Explained

The 'field' level is the base of the pyramid and represents the production floor, where devices like electric motors, hydraulic actuators, and sensors perform physical work. The next level is the 'control' level, where PLCs (Programmable Logic Controllers) and PIDs (Proportional–Integral–Derivative controllers) manage and control these devices. The PLC processes input from sensors to make decisions, while the PID maintains variables like temperature within specified limits. An everyday example of PID usage is cruise control in cars, which adjusts speed based on sensor input.

📊 Supervisory and SCADA Systems

The third level, the 'supervisory' level, introduces SCADA (Supervisory Control and Data Acquisition) systems, which combine data from previous levels and allow remote control of operations. SCADA typically includes graphical interfaces (HMIs) and can monitor multiple systems from one location. This level is commonly used in industries like water plants for controlling remote systems. Unlike HMIs that control a single machine, SCADA oversees multiple machines and processes across larger systems.

📋 MES and the Planning Level

The 'planning' level of the automation pyramid employs MES (Manufacturing Execution Systems), which monitor and manage the entire production process. MES provides oversight from raw material handling to the finished product. It enables management to make informed decisions, such as adjusting raw material orders or shipment schedules based on real-time production data. This level bridges the gap between production and business management, ensuring the factory operates efficiently.

🏢 ERP and the Management Level

The 'management' level, at the top of the pyramid, uses ERP (Enterprise Resource Planning) systems, allowing top executives to monitor and control company operations across all departments. ERP integrates various business processes like manufacturing, sales, purchasing, and finance. By connecting data from all levels of the pyramid, ERP improves company-wide efficiency and transparency, ensuring all stakeholders are aligned and informed.

🎓 Recap and Learning Resources

The video concludes with a recap of the automation pyramid, summarizing each level from the production floor (field level) up to management oversight (ERP). It emphasizes how technology facilitates automation and provides efficiency in industrial settings. Viewers are encouraged to visit RealPars' website for further training in PLC programming, with the promise of more videos to help learners secure high-paying jobs in automation and controls engineering.

Keywords

💡Automation Pyramid

The Automation Pyramid is a conceptual framework that represents the different levels of automation within a factory or industrial setting. It illustrates how various technologies and systems are integrated to optimize industrial processes, moving from field-level devices to enterprise-wide management systems. In the video, the pyramid is broken down into five distinct levels, each playing a critical role in factory automation.

💡Field Level

The field level is the base of the automation pyramid and refers to the devices, sensors, and actuators on the factory floor that physically interact with the production process. Examples include electric motors, hydraulic actuators, and proximity switches. This level is responsible for the direct operation and monitoring of machinery in the production process.

💡Control Level

The control level is the second tier of the automation pyramid and manages the devices at the field level. It uses Programmable Logic Controllers (PLCs) and Proportional–Integral–Derivative (PID) controllers to process input data from sensors and control actuators. For instance, the video mentions how PID controllers are used to maintain a constant temperature in a heater by turning it on and off based on input data.

💡PLC (Programmable Logic Controller)

A PLC is a digital computer used in industrial settings to control machinery and processes. It receives input from sensors, processes the data, and outputs commands to actuators. The PLC plays a key role in the control level of the automation pyramid by running pre-programmed tasks that control field-level devices.

💡PID (Proportional-Integral-Derivative)

PID is a type of control loop feedback mechanism often used in industrial control systems. It helps maintain a desired output, such as temperature or speed, by adjusting variables based on past, present, and future values. In the video, PID is explained through the example of cruise control in a car, where it helps maintain a constant speed by adjusting acceleration.

💡Supervisory Level

The supervisory level is the third layer of the automation pyramid, where SCADA (Supervisory Control and Data Acquisition) systems are used to monitor and control processes over large areas. This level provides oversight and allows for remote control, often through a graphical user interface (HMI), making it possible to manage large-scale operations such as water treatment plants.

💡SCADA (Supervisory Control and Data Acquisition)

SCADA is a system that gathers data from various sensors across a wide area and provides centralized control over multiple processes. It is critical for the supervisory level of the automation pyramid because it enables operators to monitor and control large industrial systems remotely. An example from the video is the use of SCADA to manage remote water pumps in a water plant.

💡HMI (Human-Machine Interface)

HMI refers to the interface that allows humans to interact with machines, typically in the form of a graphical user interface (GUI). In the automation pyramid, HMI is part of SCADA systems, enabling operators to visualize and control processes remotely. HMIs simplify complex data, making it easier for operators to manage industrial systems efficiently.

💡MES (Manufacturing Execution System)

MES is a system used at the planning level of the automation pyramid to monitor and manage manufacturing operations from raw material intake to finished products. It helps management make data-driven decisions to optimize the production process, as mentioned in the video. MES systems track production data in real-time, improving efficiency and workflow in factories.

💡ERP (Enterprise Resource Planning)

ERP is a suite of software applications used at the top of the automation pyramid to integrate all aspects of a company’s operations, including manufacturing, sales, purchasing, and finance. It gives top management a comprehensive view of business operations, allowing for effective decision-making. The video emphasizes how ERP promotes transparency and efficiency across all levels of a company.

Highlights

Introduction to the Automation Pyramid and its importance in the industrial field.

Explanation of the 'field' level, which includes devices, actuators, and sensors on the production floor.

Field level consists of physical work and monitoring, such as electric motors, hydraulic and pneumatic actuators.

Proximity switches and photoelectric switches play a part in detecting movements or materials at the field level.

Control level, where PLCs (Programmable Logic Controllers) and PIDs (Proportional–Integral–Derivative) come into play to run field-level devices.

Example of PID usage in everyday life, such as cruise control in cars and industrial applications like heaters.

The third level, known as the supervisory level, introduces SCADA (Supervisory Control and Data Acquisition) systems.

SCADA integrates multiple systems from a single location, offering monitoring and control of large-scale operations.

Difference between SCADA and HMI systems: SCADA controls multiple systems, while HMIs typically control single machines.

The fourth level, called the planning level, utilizes MES (Manufacturing Execution System) to monitor the entire manufacturing process.

MES allows real-time monitoring from raw materials to finished products, providing actionable data to management.

The top of the pyramid, known as the management level, uses ERP (Enterprise Resource Planning) for holistic business management.

ERP integrates all business processes, from manufacturing to sales, finance, purchasing, and more, promoting efficiency.

The automation pyramid facilitates seamless integration between production, management, and decision-making processes.

Conclusion: Review of how the pyramid levels—from the production floor to ERP—help streamline industrial operations.

Transcripts

Today, I will try to teach you about the Automation Pyramid.

More specifically, the devices used to make up the automation pyramid.

Before we get into today’s video, if you love our videos,

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So what exactly is the automation pyramid?

It is a pictorial example of the different levels of automation in a factory or industry.

It also serves as a visual example of how technology is being integrated into industry.

So let’s take a closer look and try to break the pyramid down.

Beginning on the bottom of the pyramid

is what we will refer to as the “field” level.

These are the devices, actuators, and sensors

that you see in the field or on the production floor.

If you think of it this way, the field level is the production floor

that does the physical work and monitoring.

Electric motors, hydraulic and pneumatic actuators to move machinery,

proximity switches used to detect that movement or certain materials,

photoelectric switches that detect similar things will all play a part in the field level.

The next level is referred to as the control level.

This is where the PLC’s and PID’s come in to play.

The control level uses these devices to control

and “run” the devices in the field level that actually do the physical work.

They take in information from all of the sensors,

switches, and other input devices

to make decisions on what outputs to turn on to complete the programmed task.

A PID is usually integrated in to the PLC

and stands for proportional–integral–derivative.

That is what can keep a variable within a set of parameters.

A common example that you probably use every day is your cruise control.

You set your cruise control to whatever speed you want,

then a set of sensors and the computer in the car will tell it when to accelerate

or decelerate according to the set speed.

A common industrial PID controlled item is a heater.

Many systems in manufacturing plants have to be heated.

We control this with a PID block within the PLC.

When a set point is entered, the PID will determine when the PLC needs to turn the heater on and off

to maintain a constant temperature.

The third level of the automation pyramid is known as the supervisory level.

Where the previous level utilizes plcs, this level utilizes SCADA.

SCADA is short for supervisory control and data acquisition.

SCADA is essentially the combination of the previous levels

used to access data and control systems from a single location.

Plus it usually adds a graphical user interface,

or an HMI, to control functions remotely.

Water plants will often employ this technology to control remote water pumps in their systems.

The important thing to remember about SCADA

is that it can monitor and control multiple systems from a single location.

It isn’t limited to a single machine like HMI’s

that we have discussed in previous videos.

The fourth level of the automation pyramid is called the planning level.

This level utilizes a computer management system

known as MES or manufacturing execution system.

MES monitors the entire manufacturing process in a plant or factory

from the raw materials to the finished product.

This allows management to see exactly what is happening

and allows them to make decisions based on that information.

They can adjust raw material orders or shipment plans

based on real data received from the systems we talked about earlier.

The top of the pyramid is what is called the management level.

This level uses the companies integrated management system

which is known as the ERP or enterprise resource planning.

This is where a company’s top management can see and control their operations.

ERP is usually a suite of different computer applications

that can see everything going on inside a company.

It utilizes all of the previous levels technology

plus some more software to accomplish this level of integration.

This allows the business to be able to monitor all levels of the business

from manufacturing, to sales, to purchasing,

to finance and payroll, plus many others.

The integration of the ERP promotes efficiency and transparency within a company

by keeping everyone in the same page.

So let's see what you have learned about the automation pyramid.

When you start at the bottom, you are starting on the production floor

with all of the sensors, motors, and actuators that make the facility run.

As you move up the pyramid, the next level is for controlling the field level.

This is where the PLCs and PIDs come in to control the devices at the field level.

The next level is the SCADA controls.

These are great for controlling and automating large areas or over long distances.

The last two levels are mostly for management.

One to control a single plant, the last that can monitor an entire company inside and out.

I truly hope this gave you a little information on the automation pyramid

and how technology is automating industry.

Make sure you check back for another new video soon.

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