Plant Operator Evaluation Using KPI Feedback for Stable Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Distributed control systems in plants lack a supporting function to allow operators to perform operations considering profitability, energy saving, and device protection, leading to instability and suboptimal management of production processes.

Innovation Solution

An operation evaluation device that calculates key performance indicators and scores operator performance from a plant management perspective, providing real-time feedback to improve operational efficiency and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If control setting value is set to maximize profitability and energy saving (lower safety margin), then productivity and energy efficiency are improved, but operational stability and reliability deteriorate

Engineering Contradiction:

Improveproduction quantityVSAvoidoperational stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements a feedback mechanism where operator actions are continuously monitored and evaluated against optimal control settings. The system provides real-time feedback on how operator decisions affect profitability, energy consumption, and operational stability, enabling continuous improvement of operator performance while maintaining optimal control parameters.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual operator judgment and mechanical control adjustments with an automated evaluation system that calculates optimal control setting values based on multiple criteria including profitability, energy saving, and operational stability. This substitution enables the system to maintain optimal settings without sacrificing either productivity or reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If operator performs operation with high safety margin, then operational stability is improved, but profitability and energy saving deteriorate

Engineering Contradiction:

Improveoperational stabilityVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The evaluation system provides feedback to operators about the energy efficiency and profitability implications of their control decisions. By showing operators how their conservative adjustments affect energy consumption and production efficiency, the system enables them to strike an optimal balance between safety margin and resource efficiency.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically adjusts control parameter recommendations based on real-time operating conditions, allowing operators to maintain appropriate safety margins while minimizing unnecessary conservatism. The evaluation system calculates optimal parameter settings that balance reliability requirements with energy efficiency and profitability goals.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If distributed control system lacks supporting function for operator evaluation, then device complexity is reduced, but operational efficiency and management quality deteriorate

Engineering Contradiction:

Improvesystem structureVSAvoidoperational efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The evaluation system is designed to automatically monitor, calculate, and provide feedback without requiring external intervention. The system self-evaluates operator performance based on pre-defined criteria and automatically generates improvement recommendations, enabling operational efficiency enhancement without proportionally increasing system complexity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The evaluation system integrates multiple functions including performance monitoring, calculation of control setting values, feedback provision, and training support into a single multi-functional module. This universal approach enables the system to improve operational efficiency across multiple dimensions without requiring separate complex subsystems for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Manufacturing precision

If control setting value is set to minimum quality passing inspection, then manufacturing precision is improved, but operational stability deteriorates

Engineering Contradiction:

Improveproduct qualityVSAvoidprocess stability

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The evaluation system dynamically determines optimal control setting values that satisfy minimum quality requirements while maintaining process stability. By continuously adjusting parameters based on real-time conditions and evaluating the balance between quality precision and stability, the system prevents operators from setting parameters too close to inspection limits where stability becomes compromised.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11500350B2Operation evaluation device, operation evaluation method, and non-transitory computer readable storage medium

Publication Date: 2022.11.15 YOKOGAWA ELECTRIC CORP

AI summary

An operation evaluation device evaluates an operation work of an operator in a plant. The operation evaluation device includes a processor that calculates a plurality of key performance indicators in process control using data related to the process control performed by the operation work of the operator in the plant and obtains a score by scoring the operation work of the operator in the plant from a viewpoint of plant management using the calculated key performance indicators, and an output device that outputs the obtained score for each viewpoint of the plant management.