The document discusses the use of a digital twin called a Capability Assurance Digital Twin to help address issues related to human operators in industrial processes. It can help reduce operator actions and alarms while improving process stability. This is achieved through modular procedural automation that digitalizes standard operating procedures. Actual case studies found reductions in operator actions by up to 96% and improvements in productivity by up to 22%. The digital twin allows for better decision making and operational execution while improving safety, reliability, and standardizing procedures. It also helps ensure operator knowledge is maintained and provides opportunities for continuous learning.

1. Kevin L. Finnan
Digital Transformation Consultant
Yokogawa
The Human Operator
Digital Twin

2. 1. Introduction - Issues
2. Capability Assurance Digital Twin
3. Benefits and Results
4. Q&A

3. Introduction

4. Human Operator Issues
▪ Semi-automated and manual processes
▪ Safety
▪ Workforce performance management, training, empowered “connected” worker
▪ Process performance
▪ DX and autonomous operations goals
Source: ASM Study
Single largest factor in plant trips and accidents is
human error
TIME UTILIZATION
Routine TASK
▪ Operation & monitoring
▪ Reporting
Improvement TASK
▪ Troubleshooting
▪ Improvement activities

5. Role of the Connected Worker
Source: Kaasinen E., et al. (2020) https://doi.org/10.1016/j.cie.2019.01.052
Real-time, data-driven decisions
and guiding of actions
Empowered feedback
Centralized action monitoring
and decision support

6. Capability Assurance Digital Twin:
Modular Procedural Automation

7. Better Decisions, Faster
The Interface of People and Physical Asset
Goal Monitoring
Knowledge Mgt.
Mgt. of Change
5
Practices
People
1
2
3
4
Decision-Making
• Forecasting (“what’s next?”)
• Prediction (“what if?”)
• Optimization (“what’s best?”)
Operational Execution
• Best practices
• Advice-based action
• Closed loop control
• Procedural automation
• Closed loop optimization
Physical AssetsSystems
Business Readiness
• Data
• Infrastructure
• Consumption
• People
Situational Awareness
• Hindsight
• Insight
• Foresight
• Oversight

8. Digital Twin
A digital twin is:
A virtual digital copy of a device, system, human or
process…
that accurately mimics actual performance
in real-time
that is executable and can be manipulated
allowing a better future to be developed

9. Capability Assurance Digital Twin - Origin
• Modular Procedural Automation, ISA TR106
• Digitalized, traceable standard operating procedures.
• Capability Assurance actual case results achieved:
96% 90% 50% 22% 18%
Reduction in
Operator Actions
Reduction in Alarms
per Operator
Reduction in Process
Unit Time to Stability
Reduction in Annual
OPEX
Increase in
Productivity

10. Time Utilization Benefits – Actual Cases
• Static alarm suppression
• Dynamic alarm suppression
• Process stabilization

11. Sustainable Benefits – Actual Cases
Improved safety
and reliability
Reduced
operation hours
while maintaining
product quality
Prevent
operation errors
and improved
operator
effectiveness
Standardize
procedures and
operation methods
regardless of
operator skill levels
Ensure
experienced
operators
‘know-how’ is
maintained in the
implemented
procedure flows
Provide
opportunities for
operators to obtain
further knowledge
about the plant
processes

12. Going Forward
Lifecycle Benefit Sustainability
Continuous Improvement
Adaptability
Enable DX
Enable IA2IA

13. Q&A