A method includes identifying one of multiple regions in a range where an output (OP) value used to implement a manipulated variable is located. The manipulated variable is associated with an industrial process, and the OP value represents an output of a downstream controller. The method also includes calculating an achievable manipulated variable (MV) limit for the manipulated variable based on the region in which the OP value is located. For example, when the OP value is located in one region, the achievable MV limit could match a user-specified limit or be based on a gain between the OP value and a value of a process variable. When the OP value is located in another region, the achievable MV limit could track the value of the process variable with a gap.