Industrial Automation Pyramid Explained: The Complete ISA 95 Guide

🎥In this video, you will learn the Industrial Automation Pyramid step by step. The Pyramid is a model inspired by the ISA 95 standard that organizes automation systems across all levels of manufacturing. You'll discover how sensors and actuators form the foundation of industrial processes, how controllers and SCADA systems bring intelligence to the operations, and how MES and ERP systems tie it all together at the top. You'll also understand the networks and protocols that make communication possible, the timing differences in data flow at various levels, and the common challenges engineers encounter in optimizing these systems.

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💬 Video Summary:

Automation Pyramid Levels
Its levels are ’Production Process,’ ’Sensing and Manipulation,’ ’Monitoring and Supervision,’ ’Manufacturing Operation Planning,’ and ’Business and Logistics.’

Automation Pyramid: Sensors & Actuators
The base level of the automation pyramid is termed the ’Production Process,’ marking the beginning. It incorporates actuators and measuring devices known as sensors, enabling interaction with the physical environment.

Automation Pyramid: PLCs & PID Controllers
Reaching the next level of the automation pyramid, ’Sensing and Manipulation,’ you encounter the indispensable contributions of PLCs and PID controllers.

Automation Pyramid: SCADA & HMIs
Upon reaching the third level of the automation pyramid, you encounter the ’Monitoring and Supervision’ phase, characterized by the extensive use of HMI and SCADA.

Automation Pyramid: MES (Manufacturing Execution System)
Moving higher on the automation pyramid, the next level represents ’Manufacturing Operation Planning.’ At this level, the Manufacturing Execution System, commonly known as MES, plays a pivotal role.

Automation Pyramid: ERP (Enterprise Resource Planning)
At the apex of the automation pyramid lies the 'Business and Logistics' level, where the ERP or Enterprise Resource Planning system is employed.

Automation Pyramid: Communication Protocols
Controlling and monitoring field devices safely is a key responsibility of the automation pyramid’s first three levels, which use robust local industrial networks for accurate and fast data communication.

The automation pyramid’s upper layers, 4 and 5, typically depend on IP-based communication protocols, where standard IT functionalities become more noticeable with each step upward.

Function Block Diagram Advantages
FBD offers the benefit of consolidating various programming lines into single or multiple functional blocks, thus streamlining the design process and enhancing organization.

Automation Pyramid: Timeframes of Layers
The automation pyramid’s foundation relies on rapid data exchange, in milliseconds or microseconds.

As you progress from level 2 to level 3, transmission frequencies are also high, with SCADA and controllers communicating every few seconds.

Data is then transferred from the SCADA system to MES and back again, which occurs at intervals of minutes or hours.

Level 4 has fewer storage requirements than Level 3. The data transfer between MES and ERP is done in intervals ranging from days to months

Automation Pyramid: Challenges
The automation pyramid restricts the flow of information to adjacent levels, meaning only those directly connected to one another can share data.

The legacy hardware can hinder communication between older and newer components of the pyramid.

The siloed data causes issues by restricting access to particular departments.

Fourth in the list of automation pyramid challenges is overprocessing data.

The automation pyramid faces the issue of delayed information updates, making it difficult for management to act quickly.

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⏰ TABLE OF CONTENTS ⏰
00:00 Automation Pyramid ISA 95
01:00 Automation Pyramid Levels
01:25 Automation Pyramid: Sensors & Actuators
02:27 Automation Pyramid: PLCs & PID Controllers
03:02 Automation Pyramid: SCADA & HMIs
04:41 Automation Pyramid: MES (Manufacturing Execution System)
05:53 Automation Pyramid: ERP (Enterprise Resource Planning)
06:36 Automation Pyramid: Communication Protocols
07:08 Automation Pyramid: Timeframes of Layers
08:20 Automation Pyramid: Challenges

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