February 17, 2025

The Mining Automation Pyramid

Digital transformation is reshaping the mining and mineral processing industries, helping operations managers tackle challenges like improving efficiency, reducing downtime, and meeting sustainability goals.

At the heart of this transformation is the Mining Automation Pyramid —a structured model that defines the hierarchy of technology systems, from field-level devices to enterprise-wide decision-making tools. By breaking down the complex layers of automation, the Automation Pyramid provides a roadmap for mining operations to adopt advanced technologies effectively and cohesively.

What is the Automation Pyramid?

The Automation Pyramid, derived from the ISA-95 standard, is a five-layer framework that describes the integration of hardware, software, and data in industrial operations. Each layer represents a specific function, with seamless communication and data flow between them ensuring efficient decision-making and operational control. Here are the five layers:

Level 0: Field Level

This foundational layer includes sensors, actuators, and other devices that directly interact with physical assets like machines and processes. These devices monitor parameters such as temperature, pressure, flow rates, and equipment status, sending real-time data to the next levels of the pyramid. Actuators, such as motors and valves, execute commands from higher levels.

In mining, sensors might track conveyor belt speeds, monitor ore grades, or measure slurry density. This data forms the raw input for automation and optimisation efforts.

Level 1: Control Level

The control layer manages real-time operations through programmable logic controllers (PLCs), distributed control systems (DCS), and other automation tools. These systems receive data from field devices and use it to execute control strategies. For example, a PLC might adjust the speed of a conveyor belt based on ore flow data to prevent bottlenecks.

In mineral processing plants, DCS systems are crucial for controlling processes like grinding, flotation, and leaching. Their ability to operate with precision ensures that operations remain within set parameters, optimising throughput and minimising waste.

Level 2: Supervisory Level

The supervisory level is dominated by Supervisory Control and Data Acquisition (SCADA) systems. These systems provide operators with real-time visualisation of processes, historical data analysis, and alarms for deviations from normal operations. SCADA systems enable quick responses to anomalies and ensure that control strategies are executed as planned.

For example, in a mining operation, SCADA may display data on crusher performance or energy consumption, allowing operators to make informed decisions to maintain optimal performance.

Level 3: Execution and Planning Level

At this level, Operational Management Execution Systems (OMES) bridge the gap between production and enterprise management. OMES handle tasks like production scheduling, material tracking, quality control, and performance analysis. By integrating data from the control and supervisory levels, OMES ensures alignment between operational activities and business objectives.

For mining operations, the OMES might track ore movement from the pit to the processing plant, ensuring that stockpiles are managed efficiently and that production schedules are met. OMEs also provide insights into equipment utilisation, helping managers identify areas for improvement.

Level 4: Enterprise Level

At the apex of the pyramid is Enterprise Resource Planning (ERP) systems, which oversee company-wide business functions. ERP systems integrate data from the lower levels to support decision-making in areas like finance, procurement, inventory management, and supply chain logistics.

In mining, ERP systems help align operational performance with broader business goals. For instance, they can forecast production outputs based on current operations, enabling better financial planning and market positioning.

Why is the Automation Pyramid Relevant to Mining?

Mining and mineral processing operations are inherently complex, involving numerous interconnected processes. The Mining Automation Pyramid provides a structured approach to managing this complexity, ensuring that data flows seamlessly across the organisation and that decision-making is informed and efficient. Here’s how each layer contributes:

1. Field Level: Enables predictive maintenance by monitoring equipment health and detecting potential failures before they occur.

2. Control Level: Improves process stability and safety, ensuring that critical systems operate reliably under varying conditions.

3. Supervisory Level: Provides real-time insights into operational performance, helping teams respond quickly to issues.

4. Execution Level: Aligns production activities with business goals, ensuring that resources are used efficiently.

5. Enterprise Level: Facilitates strategic planning by providing a holistic view of operations and their impact on financial and market outcomes.

Enhancing Digital Transformation with the Automation Pyramid

Digital transformation in mining involves adopting technologies like IoT, advanced analytics, artificial intelligence (AI), and cloud computing. ‘

The Automation Pyramid in Mining acts as a framework for integrating these technologies in a cohesive manner

IoT Integration: Sensors at the field level can collect vast amounts of data, which can be analysed using AI tools at higher levels to identify trends and optimise processes.
Advanced Analytics: SCADA and OMES systems can leverage advanced analytics to predict process outcomes and suggest improvements, enhancing operational efficiency.
Cloud Connectivity: Enterprise systems can utilise cloud platforms to enable real-time collaboration across global operations, ensuring that decisions are based on the most current data.

For example, a mining company might use IoT-enabled sensors to monitor equipment health, with data fed into AI algorithms at the enterprise level to predict failures and schedule maintenance proactively. This integration reduces downtime and lowers maintenance costs, improving overall productivity.

Overcoming Challenges in Implementation

While the Mining Automation Pyramid offers significant benefits, implementing it in mining operations is not without challenges.

Common hurdles include:

Legacy Systems: Many mining operations rely on outdated equipment and software, making integration with modern technologies difficult.
Data Silos: Disconnected systems can lead to fragmented data, hindering decision-making.
Workforce Skills: Teams may lack the expertise needed to manage and leverage advanced technologies effectively.

To address these challenges, mining operations should focus on:

Conducting digital maturity assessments to identify gaps and opportunities.
Investing in training programs to upskill the workforce.
Partnering with experts like Mipac to develop and execute a tailored digital transformation strategy.

Mipac’s Role in Automation and Digital Transformation

Mipac is at the forefront of helping mining operations leverage the power of the Automation Pyramid. With decades of experience in operational technology and process control, Mipac offers a comprehensive suite of services, including:

Instrumentation and Control Design: Ensuring that field-level devices are integrated seamlessly with control systems.
System Integration: Connecting SCADA, OMES, and ERP systems to enable cohesive data flow and decision-making.
Digital Maturity Assessments: Evaluating current operations to develop a roadmap for digital transformation.
Custom Dashboard Development: Designing intuitive PI Vision dashboards to visualise critical data and insights.

The Way Forward

For mining operations to thrive in an increasingly competitive and sustainability-focused industry, embracing the Automation Pyramid is essential. This structured framework not only enhances operational efficiency but also provides the foundation for digital transformation, enabling organisations to remain agile and competitive.

Summary

The Automation Pyramid in mining is a structured framework that defines the hierarchy of technology systems in industrial operations. It consists of five levels: field-level devices (sensors and actuators), control systems (PLCs and DCS), supervisory systems (SCADA), execution and planning systems (OMES), and enterprise-level systems (ERP). This model ensures seamless communication and data flow across mining operations, enhancing efficiency, decision-making, and digital transformation.

Ready to take your mining operations to the next level with the Automation Pyramid?

At Mipac, we specialise in helping mineral processing plants integrate advanced automation systems that drive efficiency, reduce downtime, and optimise production.

Our team of experts can guide you through the digital transformation journey—from field-level instrumentation to enterprise-level planning. Whether you need support with system integration, customised dashboards, or a comprehensive digital maturity assessment, Mipac offers tailored solutions to fit your unique needs.