An extensive study of robust and optimal tuning of PID controllers for stable non-oscillating plants is presented. It is built on a set of well defined criteria related to output performance, stability margins and control activity. Different interesting properties of the closed loop systems are observed. A set of simple tuning rules is based on these observations. These rules are compared to a couple of well established tuning methods and are shown to give well competitive results, especially when simplicity, low control activity and high-frequency robustness are emphasized. Derivative action is shown to improve performance significantly compared to PI control, with equal stability margin and a moderate increase of control activity, for most plants, including those with significant time delay. (c) 2005 Elsevier Ltd. All rights reserved.