Industrie-Automation

What is industrial automation?

Industrial automation describes the use of technical systems that control, regulate, and monitor machines and equipment without continuous human intervention. Typical building blocks include programmable logic controllers (PLCs), drives, sensors, actuators, safety controllers, and operator/visualization systems such as HMI and SCADA. Communication standards that connect individual components into a networked overall system are also part of the picture.

In intralogistics, industrial automation meets a broad range of applications: conveyor technology, sorters, automated small-parts warehouses (AS/RS), automated guided vehicles (AGVs), and fully automated high-bay warehouses are examples where automation technology increases throughput and process stability. The control level communicates with higher-level systems such as warehouse management systems (WMS) or material flow controllers (MFC), making integration the central challenge.

How does industrial automation work in practice?

A typical automation project is structured across several layers: field level (sensors, actuators, drives), control level (PLCs, safety controllers), and supervisory level (SCADA, MFC, WMS). Each layer communicates via defined protocols — such as OPC UA, Profinet, or proprietary fieldbus systems. For logistics operators, this means: the more open and standardized the interfaces, the easier it is to expand or replace systems.

During acceptance testing, a distinction is made between the Factory Acceptance Test (FAT), which takes place at the manufacturer's premises, and the Site Acceptance Test (SAT), which is carried out on-site under operational conditions. Both tests define binding performance metrics and are a prerequisite for handover to regular operations.

• Availability and redundancy: For critical warehouse systems, redundancy concepts are agreed upon to mitigate the failure of individual components.
• Maintenance and spare parts: Spare parts availability over the entire lifecycle of a system is a frequently underestimated procurement issue.
• Obsolescence: Control components are discontinued by manufacturers after a number of years; an obsolescence strategy should be incorporated into the project plan at an early stage.

What matters when making a selection?

When planning and procuring automation solutions, several criteria take center stage. Interfaces to WMS and MFC must be clearly specified, ideally in a functional specification that both parties sign as binding. Service level agreements (SLAs) govern response times and availability targets; it is worth carefully weighing manufacturer warranties against actual operational requirements.

Another point is the distinction from digitalization: automation addresses the physical and control engineering level. Digitalization goes further and encompasses the evaluation of process data, end-to-end system integration, and data-driven process management. Both disciplines complement each other, but are often to be considered separately — both conceptually and in terms of procurement responsibility.