In the era of Industry 4.0, all-in-one solutions may seem attractive, but it is a costly option with risks in the medium and long term. We interviewed David Camacho, from Mapex, to understand why following the ISA-95 model is key to efficient and hassle-free digitization.
In the world of Industry 4.0, it’s easy to get carried away with promises of all-encompassing solutions. But does it really work that way?
We spoke with David Camacho, Digital Transformation specialist in Mapex’s Pre-Sales team, to understand why it is so important to respect the different levels defined by the ISA-95 standard and what risks are assumed when this is not done correctly.
Interview with David Camacho, Digital Transformation specialist of Mapex Pre-Sales team
What exactly is the ISA-95 pyramid, and why is it so relevant in digitization projects?
ISA-95 is an international standard developed by the International Society of Automation that defines how the different technological levels of industrial automation and control should be structured and how communication between them should occur. Although it was initially developed as a U.S. standard, it has been adopted as an international standard under IEC/ISO 62264.
Its goal is to facilitate that the various systems involved in digital automation work together effectively and scalably.
Each level defined in the standard has an assigned role, specific technologies, and therefore specialists in those technologies. Respecting this structure allows for digitizing and scaling operations in an orderly manner, avoiding isolated or incompatible solutions.
How is each level structured within the ISA-95 pyramid?
ISA-95 divides industrial technology into five levels, ranging from the physical process on the plant floor to business management.
Each level has its role and, above all, its own technologies. Understanding the separation between levels is key to integrating technologies in digitization projects.
At the base, or level 0, is the physical process itself, mainly composed of machinery and operators. There is no automation or digitalization at this level yet.
Level 1 corresponds to the technologies involved in detecting and manipulating physical processes, such as sensors and actuators, which allow knowing what is happening in the machine and acting upon it. These devices connect to PLCs (Programmable Logic Controllers), which are low-level controllers capable of reacting in milliseconds.
Level 2 corresponds to HMI (Human Machine Interface) and/or SCADA (Supervisory Control And Data Acquisition) systems, which focus on machine control and supervision. They connect directly to PLCs and include an interface for humans to monitor and control in real time the status of the machinery and the processes it executes.
Up to level 2, we focus on strict control technologies of physical processes, or OT (Operational Technology).
And what happens from level 3 onwards?
From level 3, we move into technologies controlling logical processes or IT (Information Technologies). This is where software tools designed entirely for human use come into play, such as MES and ERP, which are the main tools of levels 3 and 4 respectively.
Can you explain the role of each of these solutions?
The MES no longer controls the machine or physical process directly. Its role is to manage logical or operational processes, such as production, quality, traceability, maintenance, internal logistics, etc.
To do this, it automatically collects data provided by the lower level, such as production counts, machine status signals, control parameters like pressures, temperatures, dosing or weighing data, and more.
MES transforms the data generated at the physical level into valuable information for the process, allowing the humans managing the plant to understand the process status and make decisions.
For example, knowing if the production plan is on track and reacting to delays, knowing if the manufactured product meets specifications or not, deciding on process changes to correct deviations, ensuring a smooth supply flow from warehouse to plant that eliminates waiting times, etc.
At level 4 is the ERP, which must communicate with the MES to send and receive data necessary to control the fulfillment of administrative and logistical company processes: production planning, shipping and sale of finished products, stock control and raw material purchasing, accounting and finance, human resources, etc.
What are the risks of not respecting these boundaries?
If you choose to implement a vertical solution that mixes functions from different layers within the same software tool, it is very likely that this solution will be too rigid. In the medium term, when you need to update plant machinery or make changes to production processes, you may find that the reconfiguration required to adapt to changes is almost as expensive as a new implementation from scratch.
Each level requires specific technologies, must handle its own scope, and communication between levels should be flexible and open, using protocols as universal as possible, such as the new OPC UA (Open Platform Communications Unified Architecture) standard for data exchange between OT and IT levels, or APIs (Application Programming Interfaces) for data exchange between software tools in upper levels.
Skipping this and opting for closed vertical solutions will be more costly in the medium and long term.
Is it possible for a single partner to cover all layers?
It is possible, but not with a single product or tool.
A technology partner that wants to cover the entire digitalization process should offer a specific solution for each level, with open and configurable data communication and integration between them, along with qualified technical and support personnel specialized in each level.
Only then can you guarantee that the future evolution of the business will not be limited by rigidities caused by non-standard or non-scalable solutions.
What is not recommended is for someone specialized in one layer to promise they can “extend” their solution to cover the rest, skipping the hierarchy of levels we have discussed.
What advantages are there in working with partners specialized by layer?
Many. First, the quality of service. Since each partner focuses on what they really know and master, professional service is guaranteed at all levels.
Secondly, the advantage of transparent communication between levels, thus reducing the cost of future evolutions such as new product lines, machinery replacement, etc.
In our case, Mapex includes an open and configurable data integration layer based on web service APIs that facilitates communication with any modern ERP on the market, as well as an open and configurable data capture service from the plant floor, fully adapted to the new OPC UA standard, which also includes specific protocols from machinery manufacturers and auxiliary systems such as labeling, weighing, etc.
This way, we can adapt to changes in ERP as well as changes in machinery or plant systems transparently and without disruption, because we only need to adjust our communication interfaces to map them against the new elements.
How does this impact cost savings?
Working with partners specialized by layer reduces the cost of digital transformation in the medium and long term, although at first it may seem the opposite because you are buying three or four products instead of just one.
But by purchasing the right product for each level, you ensure everything mentioned above and that your digital transformation process will support not only the company’s current situation but any future situation arising from changes in the market, the company itself, processes, machinery, laws, and regulations, etc.
This has a very important strategic value, almost incalculable.
What would be your final message to a company wanting to digitize their factory?
Bet on standard and integrable solutions, and on partners who respect the layers of the ISA-95 model.
In the digital transformation process, it’s not about having a single interlocutor, but having the right interlocutors at each level. This way, you ensure the solution can grow and evolve with your business and easily adapt to your factory’s current and future needs.
