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Gregory K. McMillan
Gregory K. McMillan retired as a Senior Fellow from Solutia Inc in 2002 and as a senior principal software engineer from Emerson Process Systems and Solutions Simulation R&D in 2023. Greg is an ISA Fellow and the author of more than 200 articles and papers, 100 Q&A posts, 80 blogs, 200 columns, and 20 books. He was one of the first inductees into the Control Process Automation Hall of Fame in 2001, and he received the ISA Lifetime Achievement Award in 2010, the ISA Mentor Award in 2020, and the ISA Standards Achievement Award in 2023.
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How Can We Improve Data Historian Use?
In the latest edition of the Ask the Automation Pros column, the pros discuss how to set up a data historian to transform data into information that can be used for process monitoring, diagnosis, prediction, optimization and continuous improvement.By: Erik Cornelsen, Hunter Vegas, Michel Ruel, Peter Morgan, Gregory K. McMillan12 October, 2026 | 12 minutes -
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Ask the Automation Pros: How Can We Enhance Control System Reliability?
In the latest edition of the Ask the Automation Pros column, the pros share strategies for enhancing control system reliability.By: Peter Morgan, Hunter Vegas, Erik Cornelsen, Gregory K. McMillan, R. Russell Rhinehart, Bob Heider, Edward J. Farmer15 September, 2026 | 13 minutes -
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Ask the Automation Pros: What University Projects Are Needed to Support Process Control?
Like a lot of things in engineering and construction, it’s hard to teach everything and risky not to, but getting it right the first time saves time and money.By: R. Russell Rhinehart, Mark Darby, Gregory K. McMillan, Peter Morgan, Michael Taube, Matthew Howard, Héctor H. Torres, Pat Dixon, Julie F. Smith, Bob Heider, George Buckbee, Michel Ruel, Edward J. Farmer24 June, 2026 | 15 minutes -
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Ask the Automation Pros: What Are the Process Control Simulation Requirements for Automation Projects?
Simulation of process control can ensure productive automation projects. But how much effort should be allocated to simulation, testing and training. ISA’s Automation Professionals weigh in.By: Erik Cornelsen, Julie F. Smith, Gregory K. McMillan, Edin Rakovic20 May, 2026 | 4 minutes -
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Ask the Automation Pros: How Can You Ensure the Best Rate of Change in the PID Manipulated Variable?
What is the best strategy to get the best rate of change in the PID for a manipulated variable, or is there a more elegant solution within the control strategy itself? Answer includes example applications and guidance on how PID tuning can meet objectives.By: Gregory K. McMillan30 March, 2026 | 16 minutes -
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Ask the Automation Pros: What Topics Should Be Covered in an Undergraduate Process Control Course?
In the latest edition of the Ask the Automation Pros column, the pros share their insights on what topics should be covered in an undergraduate first course on process control, particularly in chemical engineering, but possibly also in mechanical and electrical engineering.By: Gregory K. McMillan12 February, 2026 | 40 minutes -
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Ask the Automation Pros: What Are the Prospects for an Autonomous Process Manufacturing Unit?
In the latest edition of the Ask the Automation Pros column, the pros share their insights on prospects for an autonomous process manufacturing unit.By: Gregory K. McMillan23 January, 2026 | 15 minutes -
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Data Historians: Turning ‘Digital Landfills’ Into Strategic Assets
ISA Fellows and others discuss what’s needed to turn process data into performance improvement.By: Gregory K. McMillan14 January, 2026 | 9 minutesSponsored By International Society of Automation (ISA) -
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Ask the Automation Pros: How Can You Get the Most Knowledge from a Data Historian?
In this entry in the Ask the Automation Pros blog series, the pros answer the question of how to get the most knowledge from a data historian.By: Gregory K. McMillan16 December, 2025 | 17 minutes -
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Ask the Automation Pros: What Can Be Done to Improve the Accuracy of Totalized Liquid Mass Charge?
In the latest post in the Ask the Automation Pros blog series, the pros explain what can be done to improve the accuracy of totalized liquid mass charge.By: Gregory K. McMillan21 November, 2025 | 12 minutes -
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Ask the Automation Pros: What Are the Consequences of an Overemphasis on Reducing Project Cost?
In the latest post of the Ask the Automation Pros blog series, the pros discuss potential consequences of an overemphasis on reducing industrial automation project costs.By: Gregory K. McMillan07 October, 2025 | 16 minutes -
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Ask the Automation Pros: How Is Process Control Different from Other Industrial Control Disciplines?
In the latest post of the Ask the Automation Pros blog series, the pros discuss what makes process control different from other industrial control disciplines.By: Gregory K. McMillan09 September, 2025 | 9 minutes -
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Ask the Automation Pros: Useful Books for Process Control
In the latest post of the Ask the Automation Pros blog series, the pros discuss useful books for process control.By: Gregory K. McMillan25 July, 2025 | 19 minutes -
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Ask the Automation Pros: Dealing with Interacting PID Loops
In the latest post of the Ask the Automation Pros blog series, the pros explore how to deal with interacting PID loops.By: Gregory K. McMillan20 June, 2025 | 15 minutes -
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Ask the Automation Pros: The Past and Future of Process Control
In the latest installment of Ask the Automation Pros, the pros take a look at the past and future of process control.By: Gregory K. McMillan27 May, 2025 | 36 minutes -
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Ask the Automation Pros: How Do You Specify the Best Control Valve Characteristics?
The latest installment of the Ask the Automation Pros series from ISA describes what to consider when specifying process control valves.By: Gregory K. McMillan28 March, 2025 | 5 minutes -
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Ask the Automation Pros: Achieving the Best Override Control
The latest installment in the Ask the Automation Pros blog post series addresses how to implement the best override control.By: Gregory K. McMillan14 February, 2025 | 14 minutes -
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Ask the Automation Pros: Achieving the Best Feedforward Control
In the latest installment of Ask the Automation Pros, discover best practices to understand where feedforward control is needed and how to implement it.By: Gregory K. McMillan17 January, 2025 | 18 minutes -
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Ask the Automation Pros: Achieving the Best Cascade Control
In the latest installment of the Ask the Automation Pros blog series, automation professionals share their thoughts on achieving the best cascade control.By: Gregory K. McMillan06 December, 2024 | 19 minutes -
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Ask the Automation Pros: The Use of Artificial Intelligence in Process Control
In the latest installment of the Ask the Automation Pros blog series, experts provide thoughts about the use of artificial intelligence in process control.By: Gregory K. McMillan12 November, 2024 | 15 minutes -
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Ask the Automation Pros: The Need and Use of Simulation in Process Control
In this entry in the Ask the Automation Pros series, automation experts share their thoughts on the need and use of simulation in process control.By: Gregory K. McMillan18 October, 2024 | 19 minutes -
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Ask the Automation Pros: What Are Your Thoughts About the Use of Artificial Intelligence in Process Control?
ISA automation pros including Greg McMillan discuss neural networks, major opportunities for AI today, and potential benefits for enhancing and supporting the daily activities of process control and automation professionals.By: Gregory K. McMillan12 August, 2024 | 15 minutes -
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Ask the Automation Pros: What Are Your Thoughts About the Need for and Use of Simulation in Process Control?
Russ Rhinehart asks the automation pros for their thoughts about the need for and use of simulation in process control.By: Gregory K. McMillan02 August, 2024 | 18 minutes -
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Ask the Automation Pros: What Scan Time Is Needed for Process Control Applications?
Russ Rhinehart asks the automation pros for their thoughts about what scan time is needed in different process control applications.By: Gregory K. McMillan28 June, 2024 | 13 minutes -
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Top 10 Mistakes in pH System Design and How to Avoid Them
This article covers the top 10 major mistakes Greg McMillan has seen in pH design and installation in a neutralizer tank in a waste treatment system.By: Gregory K. McMillan30 May, 2024 | 2 minutesSponsored By International Society of Automation (ISA) -
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Ask the Automation Pros: How Can We Compute Startup Tuning for New Control Valves?
Greg McMillan discusses how to compute start-up tuning for new control valves.By: Gregory K. McMillan28 May, 2024 | 7 minutes -
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Ask the Automation Pros: How to Best Migrate from Obsolete to Modern Instrumentation and Control Systems?
Greg McMillan discusses how to migrate a project from obsolete to modern versions of instrumentation and control systems.By: Gregory K. McMillan30 April, 2024 | 8 minutes -
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Ask the Automation Pros: How Can We Improve or Eliminate Split Range Control?
Ask the Automation Pros expert Greg McMillan discusses how to improve or eliminate split range controlBy: Gregory K. McMillan05 March, 2024 | 15 minutes -
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The 5 W's of Modernizing Control Systems Future
Ask the Automation Pro's Greg McMillan discusses how to modernize control systemsBy: Gregory K. McMillan02 February, 2024 | 11 minutes -
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When are we Modernizing Control Systems?
Greg McMillan of "Ask the Automation Pros" discusses the timeframe on modernization of current control systemsBy: Gregory K. McMillan22 January, 2024 | 3 minutes -
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Digital Twins for the Virtual Plant
A bioreactor system design example shows a way forward for plant development and process optimization. This feature originally appeared in the December 2023 issue of InTech digital magazine.By: Gregory K. McMillan26 December, 2023 | 7 minutes -
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Can a Primary Loop Manipulate a Secondary Loop Valve?
"Ask the Automation Pros" Greg McMillan discusses if a primary loop can manipulate a secondary loopBy: Gregory K. McMillan01 December, 2023 | 7 minutes -
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How Can we Improve Logic Control Contact Status Awareness and Operator Response?
ISA Mentor Greg McMillan answers the question, "How Can we Improve Logic Control Contact Status Awareness and Operator Response?"By: Gregory K. McMillan04 October, 2023 | 6 minutes -
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How Do You Get the Best From the People Working on Your Project?
Greg McMillan discusses how to get the best from people working on your project in the "Ask the Automation Pros"By: Gregory K. McMillan01 September, 2023 | 5 minutes -
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Ask the Automation Pros: How Do You Improve Use of Analyzers for Continuous Control?
Greg McMillan discusses how to improve the use of analyzers for continuous controlBy: Gregory K. McMillan01 August, 2023 | 9 minutes -
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Base, Best, and Ideal Practices for Mill Optimization
Greg McMillan discusses base, best, and ideal practices for mill optimization in his July Mentor postBy: Gregory K. McMillan07 July, 2023 | 5 minutes -
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Is Data Noise in Process Control Degrading Performance?
Greg McMillan discusses the topic, "Is data noise in process control degrading performance?"By: Gregory K. McMillan23 June, 2023 | 9 minutes -
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Are We Facing Broad Change?
Greg McMillan and Russ Rhinehart discuss the idea of facing broad changeBy: Gregory K. McMillan16 May, 2023 | 9 minutes -
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How Can We Improve Control of Dead Time Dominant Applications?
From Greg McMillan and the ISA Mentor Program team.By: Gregory K. McMillan04 April, 2023 | 7 minutes -
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What are Considerations in Combining Process Control and Safety Systems?
From Greg McMillan and the ISA Mentor Program team.By: Gregory K. McMillan14 March, 2023 | 6 minutes -
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What are the Diagnostics/Expertise Needed for FOUNDATION Fieldbus?
From Greg McMillan and the ISA Mentor Program team.By: Gregory K. McMillan03 February, 2023 | 8 minutes -
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How Do We Improve Response to Continuously Changing Conveyor Setpoint?
What would be a good control strategy to regulate a process in which the setpoint is continually changing?By: Gregory K. McMillan03 January, 2023 | 8 minutes -
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What Process and Equipment Effects Need More Attention?
How can we better understand how process and equipment design and operating conditions affect automation system design, installation, and performance?By: Gregory K. McMillan06 December, 2022 | 6 minutes -
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What is Your Wish List for Achievement and Recognition? Part 2
What is your personal wish list of prospective achievements in process automation?By: Gregory K. McMillan04 November, 2022 | 7 minutes -
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What is Your Wish List for Achievement and Recognition? Part 1
What is your personal wish list of prospective achievements in process automation?By: Gregory K. McMillan04 October, 2022 | 5 minutes -
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What are the Biggest Mistakes You Have Seen? Part 5
Here we continue our series with some modeling and control mistakes.By: Gregory K. McMillan02 September, 2022 | 4 minutes -
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What are the Biggest Mistakes You Have Seen? Part 4
We continue our series with some measurement and final control element mistakes seen by Greg that are widespread.By: Gregory K. McMillan05 August, 2022 | 4 minutes -
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What are the Biggest Mistakes You Have Seen? Part 3
What are the biggest mistakes in automation system design, configuration, calibration, installation, checkout, commissioning, and maintenance?By: Gregory K. McMillan01 July, 2022 | 7 minutes -
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What are the Biggest Mistakes You Have Seen? Part 2
Mistakes often offer the greatest learning experiences. Mentor program participants share what they have seen in this four-part series.By: Gregory K. McMillan17 June, 2022 | 9 minutes -
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What are the Biggest Mistakes You Have Seen? Part 1
Mistakes often offer the greatest learning experiences. Mentor program participants share what they have seen in this four-part series.By: Gregory K. McMillan10 May, 2022 | 8 minutes -
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How Can We Improve Control Loops with Slow Signal Updates?
What can be done to smooth out the signal with a soft sensor or virtual instrument?By: Gregory K. McMillan08 April, 2022 | 11 minutes -
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How Can We Improve PID Control Loop Monitoring?
What are the work processes, techniques, solutions, and people who should be involved for comprehensive control loop monitoring?By: Gregory K. McMillan01 March, 2022 | 10 minutes -
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What Can be Done to Increase Innovation in PID Control?
How can we facilitate efforts to take advantage of the remarkable increases in the capabilities and opportunities in today’s PID controllers?By: Gregory K. McMillan04 February, 2022 | 6 minutes -
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Are First Principle Models Used for Model Predictive Control?
What commercial providers of MPC use phenomenological dynamic models?By: Gregory K. McMillan11 January, 2022 | 4 minutes -
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How is Simulation Leveraged for Qualification & Management of Change?
How does one leverage simulation to support qualification and reduce downtime as part of MOC and capital projects?By: Gregory K. McMillan24 December, 2021 | 6 minutes -
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Building Rapport with the Maintenance Engineers and Technicians
What things have been found most effective in building a rapport with maintenance technicians?By: Gregory K. McMillan26 November, 2021 | 10 minutes -
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What are the Challenges, Troubleshooting, and Future of Industrial IP?
A practical view of what the future looks like for industrial internet protocols (IPs).By: Gregory K. McMillan01 October, 2021 | 4 minutes -
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What Are the Aspects of Safe Automation Systems?
In our latest ISA Mentor Program blog, Mike Laspisa asks: What are the aspects of safe automation systems?By: Gregory K. McMillan10 September, 2021 | 14 minutes -
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What are the DP Connections for Level Measurement with Wet Leg?
The latest ISA Mentor Program blog answers the question: What is the best way to install a DP in level applications with a wet leg?By: Gregory K. McMillan03 August, 2021 | 6 minutes -
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What are the Problems and Solutions with Packaged Equipment?
Our newest ISA Mentor Program blog asks the question: What are the problems and solutions with packaged equipment?By: Gregory K. McMillan02 July, 2021 | 10 minutes -
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Increases In Instrument Application or Installation Issues
Mike Laspisa shares a Q&A with various experts regarding instrumentation specification expertise, covering topics such as selection and installation.By: Gregory K. McMillan01 June, 2021 | 4 minutes -
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The Best Level for Optimization and Organization in the Smart Factory
Automation professionals from the ISA Mentor Program answer questions about optimization and organization in smart factories.By: Gregory K. McMillan20 April, 2021 | 8 minutes -
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9 Automation Engineers' Ideas and Principles for Everyday Working Life
Automation professionals from the ISA Mentor Program share their ideas and principles for everyday working life as an automation engineer.By: Gregory K. McMillan19 March, 2021 | 9 minutes -
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What Are Some Ways to Improve and Prioritize Feedforward and Fast Feedback Control?
Automation professionals from the ISA Mentor Program answer a question about how to improve and prioritize feedforward and fast feedback control.By: Gregory K. McMillan26 February, 2021 | 7 minutes -
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What Are Some Opportunities for Wireless Measurement and Control?
An automation professional from the ISA Mentor Program answers the question: 'What are some opportunities for wireless measurement and control?'By: Gregory K. McMillan19 January, 2021 | 3 minutes -
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How Can We Improve Operator Trust in a PID Controller?
Automation professionals from the ISA Mentor Program answer the question: 'How can we improve operator trust in a PID controller?'By: Gregory K. McMillan04 December, 2020 | 9 minutes -
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Electrical Engineers in Automation: What Are the Success Stories?
Automation professionals from the ISA Mentor Program answer the question: 'Have there been many success stories of electrical engineers in automation?'By: Gregory K. McMillan10 November, 2020 | 5 minutes -
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How to Quickly Identify Tuning Mistakes
Automation professionals from the ISA Mentor Program address a question they received: 'How can one quickly identify tuning mistakes?'By: Gregory K. McMillan02 October, 2020 | 7 minutes -
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How Can We Develop and Motivate New Automation Professionals?
Automation professionals from the ISA Mentor Program address a question they received: 'How can we develop and motivate new automation professionals?'By: Gregory K. McMillan11 September, 2020 | 4 minutes -
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Why Are Engineers So Against Derivative Action?
Automation professionals from the ISA Mentor Program address a question they received: 'Why are engineers so against derivative action?'By: Gregory K. McMillan28 July, 2020 | 7 minutes -
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What Factors Affect Dead Time Identification for a PID Loop?
Automation professionals from the ISA Mentor Program address a question they received: 'What factors affect dead time identification for a PID loop?'By: Gregory K. McMillan19 June, 2020 | 11 minutes -
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Alarm Management and DCS Versus PLC/SCADA Systems
There are very few if any chemical or refinery units that would not benefit from state-based alarming.By: Gregory K. McMillan19 February, 2020 | 9 minutes -
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How to Manage Control Valve Response Issues in the Field
A sensitive flow measurement is needed to identify the installed flow characteristic online.By: Gregory K. McMillan15 January, 2020 | 5 minutes -
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How to Use Industrial Simulation to Increase Learning and Innovation
New projects expose automation professionals to more learning opportunities to continue to grow their skill sets and expertise.By: Gregory K. McMillan18 December, 2019 | 8 minutes -
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How to Avoid Using Multivariable Flow Transmitters
Coriolis meters provide the only true mass flow measurements, which offer a very accurate density measurement as well.By: Gregory K. McMillan18 November, 2019 | 4 minutes
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