PART V | LESSON 18: CONTROL PHILOSOPHY MATERIAL HANDLING ACADEMY
DRIVING QUESTION Which layer of the system owns this decision?
The five-layer controls topology as a stack. From the bottom up: Layer 1 Machine Controls (the PLC), Layer 2 Middleware, Layer 3 WCS/WES, Layer 4 WMS, Layer 5 ERP. Instructions move down; status moves up. A gold bracket marks Layers 1 and 2 as where the solutions engineer lives.

The five-layer controls topology. Instructions move down, status moves up, and your working knowledge is deepest at the bottom two layers.

Who Decides What

The decisionLayer that owns it
Release this wave to the floorWMS, L4
Sequence orders into batchesWES if present, else WMS
Divert this carton to lane 5WCS decides L3; PLC fires L1
Stop this zone, it's jammedPLC, local logic, L1
Format the read for the WMSMiddleware, L2
DESIGN PRINCIPLE Locate the decision before you touch the steel.