DCS Event Log Analysis for SOP Extraction and Operator Intent
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Solution Overview
Problem
Conventional event analysis systems struggle to accurately extract and compare operation records from event logs with Standard Operation Procedures (SOPs, especially when SOPs are abstract and operation methods vary among DCS operators, leading to difficulties in standardizing operations and estimating operation procedures.
Innovation Solution
The event analysis device and system decompose event logs into basic unit operations and unit operations, then cluster and generate operation sequences to estimate the structure of operation procedures, allowing for the visualization of sequential and parallel operations, and the creation of standardized SOPs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional event analysis systems extract operation records from event logs, then individual event log units can be obtained, but it is difficult to extract abstract operation contents and operation intentions
Solution Approach 1:
The patent segments operation sequences into hierarchical levels: individual event log units are grouped into basic unit operations, which are further grouped into unit operations, and finally into operation sequences. This segmentation allows extraction of both detailed individual events and abstract operation patterns simultaneously, resolving the contradiction between precise extraction and information loss.
2Ease of manufacture
If SOPs are written with rough operation procedures, then they are easier to create, but different interpretations occur leading to operation variations
Solution Approach 1:
The patent creates standardized operation procedure templates by copying and structuring typical operation patterns extracted from actual event logs. These templates provide concrete, repeatable operation sequences that can be systematically applied, ensuring consistency while maintaining ease of creation through template reuse rather than manual writing of each procedure.
3Measurement precision
If event logs are analyzed at individual unit level, then detailed operation records are obtained, but it is difficult to compare with abstract SOP descriptions
Solution Approach 1:
The patent introduces a hierarchical dimension to operation analysis, organizing events from individual units to basic unit operations, then to unit operations, and finally to operation sequences. This multi-dimensional structure allows comparison at multiple abstraction levels, enabling both detailed individual event analysis and high-level SOP compatibility simultaneously.
4Ease of operation
If manual operation methods are not standardized, then operator flexibility is maintained, but operation variation increases making SOP improvement difficult
Solution Approach 1:
The patent implements feedback mechanisms by automatically analyzing actual operator operations from event logs, comparing them against standardized templates, and identifying deviations. This feedback loop enables continuous improvement of SOPs while maintaining operator flexibility, as operators can see how their variations compare to standards and learn from the analysis results without being rigidly constrained.
Data Source
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AI summary
An event analysis device includes: a one or more event collector configured to collect event log data representing an operation history by a DCS operator; an event analyzer configured to analyze the event log data, and to extract one or more basic unit operations or one or more unit operations representing an operation method based on operations of the DCS operator or an operation intention based on operations of the DCS operator; an operation sequence extractor configured to extract one or more operation sequences which the one or more basic unit operations or the one or more unit operations are aligned in accordance with time order in every service time period; an operation clusterer configured to cluster the operation sequences based on similarity among the operation sequences extracted in every service time period; and an operation procedure generator configured to analyze the operation sequences clustered in same type, and to estimate a structure of the operation procedure based on the operation of the DCS operator.