Balancing automated systems with manual tasks can be achieved by clearly defining roles, creating smooth interfaces between systems, and encouraging feedback loops. For example, in a manufacturing plant, automated systems can control temperature, pressure, and flow rates on a production line, adjusting variables to keep operations running smoothly. However, manual intervention is required when there are system alerts, malfunctions, or when fine-tuning is needed for complex operations that the automated system cannot adjust on its own. Operators may also manually inspect equipment during scheduled maintenance or adjust parameters based on real-time data analysis, ensuring both automation and manual processes work together efficiently.

The control system for any process may be designed in an integrated fashion i.e there should be some manual override/backup mechanism along with the automatic (programmed) operation (most of the loop controllers own this design). When controller's malfunction or process deviation occurs on auto, the control system switches itself to a tracked or predetermined manual mode thus enabling the human operator to handle it manually. Now the control system tracks the manual operation and resumes its auto-mode in a bump-less mechanism as soon as the operator decides, after the corrective actions taken against the diagnosed faults. Two factors: 1. Selection of controllers and algorithm 2. Training of operators on control system & process dynamics