A simple yet effective and robust identification method is presented using process step responses for process identification that can provide a continuous transfer function with time-delay without iteration. A cascade relay provides accurate and reliable more points on the process frequency response. The internal model principle is employed to design single-loop controller of PID or high-order types with best achievable control performance for controller tuning, e.g. both single and multivariable cases are covered. The process identification and control design portions can be easily integrated into a control system auto-tuning package. Further, a general control scheme for disturbance rejection is given which can significantly improve disturbance rejection performance over conventional feedback systems with time delays. Practical issues such as noises, real-time implementation and tuning guidelines are also provided. The present invention provide general, systematic, effective, and applicable methods for process identification and control for a wide range of industries such as process and chemical plants, food processing, waste water treatment and environmental systems, oil refinery, servo and mechatronic systems, where a system model is needed for analysis, prediction, filtering, optimization and management, and / or where control or better control is required for their systems.