Automation Levels
Level 1 (Process Control):
Level 1 integration in automation includes device / PLC controlled network on independent equipment control.
Level 2 (DCS Integration):
Level 2 integration in automation includes all standalone PLC / devices integration with centralized control system i.e. DCS (Distributed control system) system which consist engineering station, continuous historian, alarm / event management, operator interface and batch management.
Level 3 (MES / eBPR Integration):
Level 3 integration in automation is MES (Manufacturing Execution System) integration over DCS, which consist, batch historian, recipe management, batch execution, user interface, configuration management, and workflow management.
Level 4 (ERP / SAP Integration):
Level 4 integration in automation is ERP / SAP integration over MES system. MES will plan the resource automatically using the workflow and resources by recipe configuration.
System Architecture
Integration structure
Importance of Using the MES (Manufacturing Execution System)
1. Improve your control
over quality, speed and waste.
2. Create a flexible
real time working environment
3. Manage capacity and
cycle time of batch for efficient and consistent growth
4. Automate records
management and Minimization of data integrity
5. Analyze
overproduction, excessive inventory, faulty process and more.
6. Reducing human error
and increasing paper less tracking through out the production environment
7. Reduce the cost of
regulatory compliance and minimize the impact of recall
8. Share the real time
data on data and shop floor status
9. Realize the
efficiency of global operating standards and batch failure tracking
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