When designing an automated system that will interface with human operators, it is wise to develop the system as if it will be used by kindergarteners with gorilla-like strength. Structure the workspace to eliminate problems at their source, remove friction, and create a streamlined process as part of effective industrial automation system design.
Develop user interfaces with attention to intuitive controls, fast responses, and actionable feedback. When systems are lean, responsive, and easy to understand, they are less likely to incite frustration from operators and lead to a happier, more productive shift.
In Part 1, we covered protecting the equipment, safety guarding, and smart product selection. Now in Part 2, let’s talk about designing the user experience and lean process flow so your operators (and your systems) stay happy and productive.
First, fit the space and job to the people working. Engineer lines in chronological order for linear, continuous flow, and aim to eliminate backtracking and bottlenecks, an approach that aligns with strong controls integration services.
Keep the process simple. Aim for five or fewer steps per operator task. That includes every button press, data entry, or single extended repetitive action.
Optimize space so materials are within easy reach and operators can work with natural, comfortable movements, without long walks between stations or crossing paths with coworkers.
Mount signage, display screens, and HMIs in locations where operators can see them without turning around, craning their necks, or shifting position. On touchscreens, place the most frequently used buttons toward the bottom, below display areas, to reduce arm movement and avoid obstructing information.
Give operators tools with good ergonomic design, comfortable grips, and low operating force. Less strain means less fatigue and faster work.
There’s a great example of lean process design in the movie The Founder, in which McDonald’s creators tested various kitchen layouts chalked out on a tennis court with their staff until they found the most efficient workflow.
Key principles include:
We streamline workflow by making each interface feel intuitive, fast, and nearly impossible to misuse.
Laggy interfaces cause operator frustration and hasty actions to compensate, which leads to increased errors. Ever clicked a button, had nothing happen, and then clicked it several more times, only for the system to lock up from too many requests?
If a button triggers a process that takes time, disable it temporarily and re-enable it once the action completes. Optimize and test scripts, queries, and background processes so the interface stays responsive.
The less friction in the workflow, the happier your operators will be, and the longer your equipment will last. (They won’t be smashing it out of frustration.)
Avoid network dropouts during runtime, prevent errors where possible, and resolve issues quickly when they occur. When an error occurs, be sure to provide a helpful alert to the operator with not only an explanation, but more importantly the appropriate action or workaround they should take, an important part of well-designed industrial control systems.
Boost intuitiveness with:
Keep colors neutral, pastel, or gray for most screen elements. Reserve brighter colors for required actions, warnings, and alerts. Follow IEC and ISO color-coding standards, and use high-contrast combinations like black on yellow or white on dark blue for readability.
For multilingual teams, include an on-screen language selector and consider posting key signage in multiple languages.
If your facility has high operator turnover, mistakes will naturally be more common as new hires are learning.
Helpful, highly visible signage that reinforces key process steps, highlights common pitfalls, and provides safety reminders can make a meaningful difference in both performance and safety.
Read Part 1 to learn more about protecting equipment from operators or bad actors, protecting operators from equipment, and selecting rugged, reliable devices.
If you’re evaluating your current systems or planning improvements, reach out to our team to talk through your application.
About the author
Elizabeth Engler is a Controls Integrator with diverse experience across controls design, programming, and software development. She enjoys logical challenges, user interface design, and programming machines to bring customer's visions to life. In her free time, Elizabeth enjoys gardening, mysteries, movies, and time with family.
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About Hallam-ICS
Hallam-ICS is an engineering and automation company that designs MEP systems for facilities and plants, engineers control and automation solutions, and ensures safety and regulatory compliance through arc flash studies, commissioning, and validation. Our offices are located in Massachusetts, Connecticut, New York, Vermont, North Carolina and Texas and our projects take us world-wide.