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What are the best ways to minimize human error in industrial processes with DCS applications?

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Human error is one of the most common and costly causes of accidents, failures, and inefficiencies in industrial processes. To prevent or reduce human error, many industries rely on distributed control systems (DCS) to automate and monitor their operations. DCS are networks of controllers, sensors, actuators, and communication devices that control complex and dynamic processes in real time. However, DCS applications are not immune to human error, and they require careful design, implementation, and maintenance to ensure safety and performance. In this article, we will discuss some of the best ways to minimize human error in industrial processes with DCS applications.

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1 Understand human factors

One of the first steps to minimize human error is to understand the human factors that affect the interaction between humans and DCS applications. Human factors are the physical, psychological, social, and organizational aspects that influence human behavior and performance. Some of the human factors that can lead to error are fatigue, stress, distraction, boredom, overconfidence, complacency, lack of training, poor communication, and conflicting goals. By identifying and addressing these factors, you can improve the human-machine interface (HMI) and the work environment to reduce the likelihood and impact of human error.

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Greg Potter

Senior Automation Advisor - Operational Optimization - OT Cyber Security - Project Managment
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I had the very good fortune of spending more than 10 years of my career working for an operating company that was a member of the Abnormal Situation Management Consortium (ASM), which was formed in response to the US Chemical Safety Board recommendations coming out of numerous catastrophic incidents in the O&G and Chemical industries. The focus of the resultant ASM guidelines is on leveraging human factors engineering principles in the design of controls and operational procedures. Key areas that contribute to reducing human error include: 1) Effective operator interface systems 2) Effective alarm systems 3) Effective operating procedures There are 4 ASM guidelines that serve a great foundation to understanding key considerations.

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Ranga Seshadri

Operations & Information Technology (OT/IT) Integration Consultant | Business Translator. “ Innovating manufacturing through integrating information and facilitating first principles thinking.”
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Current UX designs incorporate cognitive science to reduce human error. Use of data science and ML techniques can pinpoint trouble areas instead of getting lost in avalanche of alarms. Use of ML on alarm and events data collected has also identified different states and transitions that helps to tweak the state based alarming.

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2 Design user-friendly HMI

The HMI is the interface that allows humans to interact with the DCS applications, providing them with displays, alarms, controls, and feedback. To facilitate operator tasks, enhance situational awareness, and support decision-making, a user-friendly HMI should be designed. This includes clear and consistent symbols, labels, and colors; avoiding information overload and clutter; providing relevant, accurate, and timely information; prioritizing and categorizing alarms according to severity and urgency; using multiple modes of presentation; providing feedback and confirmation for actions; enabling easy navigation and access to information; and adapting to different levels of operator experience and preference.

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Carl Lee Tolbert, PhD, CMRP

Leading Voice in Industrial Systems & AI | AC Drive Performance & Reliability Expert | Published Research Scholar | Social Media Exponent | Lecturer
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The difficulty for DCS is the amount of data to display on a single screen. There are two approaches. The first is to imitate the original system where the operators are experienced, and they wish to stay the same as possible. So, the design focuses on integrating new features with the original design. The second approach is a new system where I focus on the most significant functions and break them into a single overview, akin to navigation for the detailed screen needed for each function. In both cases, feedback during operation and the design adaptation will take much time and effort. Generally, five revisions were routine, depending on the complexity of the system and the number of process control details and subsystems.

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3 Implement standard operating procedures

Standard operating procedures (SOPs) are essential for minimizing human error in industrial processes with DCS applications. These documented instructions and guidelines provide operators with the expected steps, actions, and outcomes for different scenarios, and should be based on best practices and industry standards. The language used should be clear, concise, and simple. Additionally, SOPs should be reviewed and updated regularly, made available and accessible to the operators, and followed and enforced by the management and the operators.

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4 Train and empower operators

Training and empowerment are essential for minimizing human error in industrial processes with DCS applications, as they boost the operators' abilities, understanding, and assurance. Training should be ongoing and comprehensive, encompassing both technical and non-technical aspects that are tailored to the specific DCS applications and processes. Additionally, it should include realistic simulations and scenarios, as well as evaluations of the operators' performance and feedback. Empowerment should involve empowering the operators to take responsibility and initiative, involving them in the design, implementation, and improvement of the DCS applications and processes. Moreover, they should be provided with the authority and resources to solve problems and make decisions. Finally, their achievements and contributions should be recognized and rewarded.

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Greg Potter

Senior Automation Advisor - Operational Optimization - OT Cyber Security - Project Managment
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The first thing that needs to happen to "Empower" operators is get them out of reactionary mode. No amount of policies, incentives or training can overcome poor HMI design. Once the operators have a clear view of the plant / process trajectory based on forward looking trends and indicators they are put in a position of proactively guiding the plant / process as opposed to reacting to events after they have happened. Focusing on providing the operators with resources that allow them a forward looking perspective on the plant / process is the most empowering thing you can do!

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5 Monitor and audit processes

Monitoring and auditing are essential processes for collecting, analyzing, and reporting data and information about the performance and status of the DCS applications and processes. These processes help to minimize human error by enabling the detection, correction, and prevention of errors and deviations. To ensure successful monitoring and auditing, they should be continuous and systematic, based on predefined indicators and criteria, using reliable and valid methods and tools. Additionally, it’s important to communicate the results and feedback to the relevant stakeholders as well as implement corrective and preventive actions.

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