Event Analyzing Device for Plant Manual Operation Standardization
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Solution Overview
Problem
In industrial plants, manual operations often vary due to changes in operating methods over time, leading to inconsistencies in standard operating procedures (SOPs), which can result in differing interpretations among operators, especially during troubleshooting or unsteady operations, where specific manual operation methods are not clearly described.
Innovation Solution
An event analyzing device and system that automatically extracts criteria for manual operations by analyzing event logs, standardizing procedures by identifying manual operation methods and intentions, and constructing standardized manual operation procedures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation procedures are updated to reflect changes in operating methods, then the SOP remains current and relevant, but variations in interpretation among operators may still occur due to insufficient detail
Solution Approach 1:
The patent transforms qualitative operational descriptions into quantitative parameters by extracting specific values (e.g., valve opening percentages, flow rates, temperatures) from event logs. This parameterization ensures that SOP updates reflect actual operating changes while providing precise, unambiguous instructions that eliminate interpretation variations among operators.
Solution Approach 2:
The system automatically copies actual operational data from event logs to create standardized procedure descriptions. By replicating real operator actions and parameters from the logs, the SOP captures current practices accurately while standardizing the representation across all operators, ensuring both currency and consistency.
2Ease of operation
If detailed manual operation methods are specified in SOP to eliminate interpretation variations, then operational consistency improves, but the complexity of creating and updating SOP increases
Solution Approach 1:
The system enables self-service SOP creation by automatically extracting operational data from event logs and generating standardized procedure descriptions without requiring manual compilation. The system serves itself by using its own operational data to create the SOP, eliminating the need for complex manual documentation processes while maintaining high detail and consistency.
Solution Approach 2:
The patent replaces the manual mechanical process of SOP creation and updating with an automated information processing system. Event logs are automatically analyzed, parsed, and transformed into standardized procedure descriptions, substituting human effort with computational processes that reduce complexity while improving consistency.
3Productivity
If event logs are analyzed to automatically generate SOP, then SOP creation efficiency improves, but the ability to capture operator skill and judgment in determining process states becomes limited
Solution Approach 1:
The system incorporates feedback loops where extracted operational data is used to refine and update SOP automatically. By continuously analyzing event logs and comparing actual operations with standardized procedures, the system captures evolving operator expertise and adjusts SOP accordingly, maintaining efficiency while preserving skill-based knowledge through iterative refinement.
Data Source
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AI summary
An event analyzing device (10) includes an event collector (101) configured to collect log data of a manual operation event performed by an operator of a plant, an event analyzer (103) configured to analyze a manual operation method or a manual operation intention of the manual operation event based on the log data, a manual operation sequence extractor (104) configured to extract the manual operation method or the manual operation intention for each predetermined period as manual operation sequences in order of time, a manual operation sequence classifier (105) configured to classify the manual operation sequences in which manual operations are in a similar order from among the manual operation sequences, a manual operation procedure constructor (106) configured to construct a manual operation procedure of the operator based on the manual operation sequences, a process data collector (1081) configured to collect process data of the plant, and a manual operation condition estimator (1083) configured to estimate an execution condition under which manual operations of the manual operation procedure constructed are performed.