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Kevin L. Finnan
Digital Transformation Consultant
Yokogawa
The Human Operator
Digital Twin
1. Introduction - Issues
2. Capability Assurance Digital Twin
3. Benefits and Results
4. Q&A
Introduction
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
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
Capability Assurance Digital Twin:
Modular Procedural Automation
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
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
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
Time Utilization Benefits – Actual Cases
• Static alarm suppression
• Dynamic alarm suppression
• Process stabilization
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
Going Forward
Lifecycle Benefit Sustainability
Continuous Improvement
Adaptability
Enable DX
Enable IA2IA
Q&A

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The Human Operator Digital Twin

  • 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
  • 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