Method and apparatus for optimizing process control systems

A system for optimizing standard operating procedures for an industrial automation process control system comprising one or more processors, and a plurality of field devices, including at least one of sensors and actuators, the system comprising:

• a processor implemented operator interface;
• a control system process monitor configured to:
• record a sequence of control system operator actions, wherein one or more operator actions within the recorded sequence of control system operator actions are detected based on at least one operator input received at the processor implemented operator interface;
• identify a control system process corresponding to the recorded sequence of control system operator actions;
• and
• retrieve a standard operating procedure associated with the identified control system process, wherein said standard operating procedure defines a sequence of control system operator actions;
• a key performance indicator monitor configured to:
• determine a set of key performance indicator values (KPI values) associated with the recorded sequence of control system operator actions, wherein one or more KPI values within the determined set of KPI values are determined based on state changes detected at the plurality of field devices;
• and
• retrieve a set of KPI values associated with the standard operating procedure;
• a performance analyser configured to determine a first set of deviations between (a) the recorded sequence of control system operator actions and (b) the sequence of control system operator actions defined by the standard operating procedure;
• determine a second set of deviations between (c) the set of KPI values associated with the recorded sequence of control system operator actions and (d) the set of KPI values associated with the standard operating procedure;
• and
• responsive to one or both of the first set of deviations and second set of deviations conforming to a predefined modification criteria, modifying the standard operating procedure to reduce deviation between (e) the recorded sequence of control system operator actions and (f) control system operator actions defined by said standard operating procedure,
• wherein modifying the standard operating procedure comprises replacing said standard operating procedure with the recorded sequence of control system operator actions.

A computer program product for optimizing standard operating procedures for an industrial automation process control system having a plurality of field devices, including at least one of actuators and sensors, comprising a non-transitory computer usable medium having a computer readable program code embodied therein, the computer readable program code comprising instructions for:

• recording a sequence of control system operator actions, wherein one or more operator actions within the recorded sequence of control system operator actions are detected based on at least one operator input received at a processor implemented operator interface;
• identifying a control system process corresponding to the recorded sequence of control system operator actions;
• determining a set of key performance indicator values (KPI values) associated with the recorded sequence of control system operator actions, wherein one or more values within the determined set of KPI values are determined based on state changes detected at said plurality of field devices;
• retrieving a standard operating procedure associated with the identified control system process, wherein said standard operating procedure defines a sequence of control system operator actions;
• retrieving a set of KPI values associated with the standard operating procedure;
• determining a first set of deviations between (a) the recorded sequence of control system operator actions and (b) the sequence of control system operator actions defined by the standard operating procedure;
• determining a second set of deviations between (c) the set of KPI values associated with the recorded sequence of control system operator actions and (d) the set of KPI values associated with the standard operating procedure;
• and
• responsive to one or both of the first set of deviations and second set of deviations conforming to a predefined modification criteria, modifying the standard operating procedure to reduce deviation between (e) the recorded sequence of control system operator actions and (f) control system operator actions defined by said standard operating procedure,
• wherein modifying the standard operating procedure comprises replacing said standard operating procedure with the recorded sequence of control system operator actions.