We study the relationship between heuristics and standard tool application in the design of process control systems. This relationship is illustrated by classical control history examples. Features of modem engineering objects are highlighted that challenge classical control approach and leave substantial space for creative solutions. We focus on inevitable heuristics in control design for modem complex process systems. The study suggests new systematic approach to heuristic control design. The approach is based on simplification technique and follow three steps. First, certain assumptions (e.g. negligible nonlinearity or dynamic behavior) help to develop the simplified model and problem setup. Second, standard control design is performed on this reduced model. Third, the perturbation theory methods help to find corrections to the obtained control to cope with the real plant. Special attention is given to the paradigm of concurrent (or integrated) plant and control design. The study suggests finding a proper compromise between investments in the process and its control. Several cement manufacturing process examples demonstrate that this method can generate better effect comparing to autonomous approach. (C) 2015 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.