Analytical generator of key performance indicators for pivoting on metrics for comprehensive visualizations

• US 8,055,375 B2
• Filed: 09/30/2008
• Issued: 11/08/2011
• Est. Priority Date: 09/30/2008
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Tooke, Ian Edward, Albert, Kevin John, Baier, John Joseph, Fuller, Bruce Gordon, McGreevy, Robert Joseph, Pantaleano, Micheal John, Pingel, Jan
• Primary Examiner(s): Chaki; Kakali
• Assistant Examiner(s): Booker; Kelvin
• Application Number:
  US12/242,140
• Publication Number:
  US 20100082125A1
• Time in Patent Office: 1,134 Days
• Field of Search: 700/47, 700/28, 700/14, 700/159, 700/161, 700/160, 700/108, 700/173, 700/174, 382/159
• US Class Current: 700/173
• CPC Class Codes: G05B 23/0272 Presentation of monitored results, e.g. selection of status reports to be displayed; Filtering information to the user

Abstract

A guidance system of an industrial process captures process parameter data that is correlated with a human-machine interface (HMI) in order to learn how an experienced operator selects visualizations of key performance indicators (KPI) in order to take a corrective action to address an abnormal or non-optimal performance condition. Such solution learning can be invoked to recognize onset of another similar occurrence and responding by suggesting visualizations utilized by the experienced operator to diagnose the problem. Analytics can further determine which visualizations provided useful information relative to the problem. In addition, the corrective action can be suggested or automatically implemented.

Claims

1. A method for guiding an operator of an industrial process by learning from expertise of another operator, the method comprising:

accessing parameter data of an industrial process;

accessing human-machine interface (HMI) data and correlating with the accessed parameter data;

determining that the parameter data characterizes a problem warranting operator intervention in the industrial process;

tracking a process visualization utilized by an operator and a subsequent control correction made by the operator;

defining a solution comprising a key performance indicator (KPI) indicative of the problem as characterized;

defining the solution further comprising;

detecting a plurality of process HMI visualizations utilized by operator;

comparing correction parameters presented by the plurality of process HMI visualizations against an optimum set of historical parameter data compiled from the parameter data; and

weighting one of the plurality of process HMI visualizations for the solution including generating a weighted HMI visualization based on departure of a selected KPI in a presented HMI visualization from the optimum set of historical parameter data; and

presenting the weighted HMI visualization for the KPI, and a control correction that addresses the KPI.

2. The method of claim 1, further comprising:

monitoring parameter data of a real-time industrial process; and

identifying a condition in the parameter data matching the solution.

3. The method of claim 2, further comprising prompting an HMI device to present the weighted HMI visualization associated with the KPI.

4. The method of claim 2, further comprising prompting an operator to perform the control correction addressing the KPI.

5. The method of claim 2, further comprising automatically causing the control correction addressing the KPI.

6. The method of claim 1, further comprising defining the solution by interacting with a real-time industrial process, wherein parameter and HMI data are stored.

7. The method of claim 1, further comprising defining a solution context for the solution by accessing historical parameter data and historical HMI data.

8. The method of claim 1, further comprising determining that the parameter data warranted operator intervention retroactively after detecting the control correction.

9. The method of claim 8, further comprising determining that the parameter data warranted the operator intervention by detecting an HMI alert to the operator.

10. The method of claim 8, further comprising selecting a HMI visualization for the context of the parameter data affected by the control correction.

11. The method of claim 1, further comprising:

storing parameter data comprising fixed context data defined a priori for HMI visualization control and comprising flexible context data selected for storage by an end user device; and

defining a solution based at least in part on the flexible context data.

12. The method of claim 1, further comprising:

interfacing to a disparate plurality of networked sources of parameter information; and

synchronizing the networked sources of the parameter information with the parameter data for correlation.

13. The method of claim 1, wherein the weighting is based on departure of a selected KPI in a presented HMI visualization from an optimum set of historical parameter data.

14. An apparatus for guiding an industrial process, comprising:

a first network interface configured to access and store parameter data of an industrial process;

a second network interface configured to access at least one human-machine interface (HMI) data correlated with the parameter data; and

a key performance indicator (KPI) guidance system configured to;

determine that the parameter data characterize a problem warranting operator intervention in the industrial process;

track a process visualization utilized by an operator and a subsequent control correction made by the operator; and

define a solution comprising a KPI indicative of the problem as characterized, wherein the KPI guidance system, to define the solution, is further configured to;

detect a plurality of visualizations selected by the operator;

compare parameters presented by the plurality of visualizations against an optimum set of historical data;

weight one of the plurality of visualizations based on departure of a selected KPI in a presented visualization from the optimum set;

define a visualization for the KPI; and

define a control correction that addresses the KPI.

15. The apparatus of claim 14, wherein the first and second network interfaces are further configured to monitor parameter data of the industrial process in real-time, and

the KPI guidance system is further configured to identify a condition in the parameter data matching the solution in real-time.

16. The apparatus of claim 15, wherein the KPI guidance system is further configured to at least one of prompt an HMI device to present the visualization or prompt an operator to perform the control correction.

17. The apparatus of claim 14, wherein the KPI guidance system is further configured to define a context of the solution by accessing historical parameter data and historical HMI data.

18. The apparatus of claim 14, further comprising a historical data storage device configured to store parameter information and HMI data.

19. The apparatus of claim 14, wherein the KPI guidance system is configured to weight based on departure of a selected KPI in a presented visualization from a KPI set obtained when the industrial process is performing as required.

20. An industrial process system, comprising:

a process component configured to generate parameter data;

a human-machine interface (HMI) configured to display the parameter data and provide operator controls for the process component;

a storage device configured to retain historical parameter data and HMI data;

a first network interface configured to access real-time parameter data of an industrial process;

a second network interface configured to access in real-time the HMI data correlated with the historical parameter data; and

a key performance indicator (KPI) guidance system configured to communicate via the first and second network interfaces and further configured to;

determine that the real-time parameter data characterize a problem warranting operator intervention in the industrial process,

track a process HMI visualization utilized by an operator and a subsequent control correction made by the operator;

define a solution comprised of a KPI indicative of the problem as characterized, a solution HMI visualization for the KPI, and a control correction that addresses the KPI, wherein, to define the solution, the KPI guidance system is further configured to;

detect a plurality of process HMI visualizations selected by the operator;

compare parameters presented by the plurality of process HMI visualizations against an optimum set of the historical parameter data;

weight the plurality of process HMI visualizations to generate a plurality of weighted process HMI visualizations based on departure of a selected KPI in a presented HMI visualization from the optimum set; and

select based on the plurality of weighted process HMI visualizations a solution HMI visualization.