Design machines with a focus on user's abilities and needs
Article#: 00063
Date: 2021-06-30
Author: Radim
Machine builders must find a way to ensure that the operation of the machine is appropriate for the user, instead of forcing the user to adapt to the machine.
The aim is to reduce human errors, increase productivity and increase the safety and comfort of the user when interacting with the machine.
Take into account the tasks of all users with the roles of operator and maintenance engineer.
Make sure the parts that the users need to see or need to get to are actually visible and reachable.
Make sure that users are protected from potential hazards.
Choose controls and indicators that are appropriate for their purpose and easy to use.
Provide the user with sufficient work space.
Avoid obstacles in the path of the user's body (head, hands, elbows, feet, knees, etc.).
Consider the different sizes of the user's figure.
Consider the appropriate placement of elements for left-handed and right-handed users.
Arrange the items so that they are accessible or visible to users without having to move from place to place.
Ask yourself questions:
Does the operator have to see the machine while operating it?
How can the machine alert the operator to the need for intervention?
It is ideal if we can design optimal ergonomics as early as the construction phase of the machine.
However, it still has to be checked whether ergonomics are also suitable in the next phases of project development.
It is advantageous if the execution of user tasks can be tested on a simulator, for example before the actual machine is completed.
Explore how users complete their tasks.
Ask the users how the ergonomics suit them and if they would change anything.
Gain experience and optimize ergonomics!
© Radim-Automation, 2020–2025. All rights reserved.
Sharing of this article is permitted with proper attribution (link to the original page).
Related previous articles:
- Learn from your journey!
- Why do automation projects fail?
- Collect all the requirements and sort them!
- Who will operate?
- Functional and intuitive HMI
- HMI and PLC applications should grow together
- I can see what you can not see
- Safety first!
- Do the right things and do them right!
- Define test scenarios and test cases continuously!
- Don't make it worse!
- Write a project diary!
- Keep the answers to the question "Why"
- Everything is difficult until it becomes easy
- Realize every good idea ASAP!
- Industrial evolution - Listen to your customers and follow new trends!
- Stay alert!
- What does the customer need?
- Don't disappoint your customer!
- Ask questions!
- Request bottom-up input!
- Focus on target!
- Think on paper!
- Don't hide any problem!
- Check the result!
- Keep it simple!
- Don't leave a work package half-finished!
- Success is not a matter of coincidence
- Development is evolution
- Follow the vision!
- Don't neglect and don't skip any step!
- Transparency and reliability
- From an idea to a consistent system
Related next articles:
- Think critically!
- Are there also any disadvantages?
- A good concept = Complete set of suitable solutions
- Hardware concept
- Machine modularization
- Knowledge gained from a completed project is priceless
- Safety relays versus safety PLC
- Design considerations for effective HMIS
- Clear signals
- Talk to operators
- It doesn't work without sensors
- PLC network diagram
- Keep the documentation up to date throughout the project
- Graphic designer
- High Performance HMI
- HMI - Have a consistent style
- HMI - Don't overdo it with complex design
- Hidden dangers during commissioning
- HMI is not a web page
- Choosing an HMI display
- HMI layout and correct display size
- HMI layout design
- HMI navigation
- HMI - back and forward navigation buttons
- HMI – Don’t hide anything
- HMI - annoying pop-up windows
- HMI - colors in the visualization
- What makes an HMI intuitive?
Comment#: 00001
Date: 2021-06-30
User: Radim
"Sample identified non-conformities:
- During work performance (and specifically when handling machine controls), additional personnel enter the hazard zone and become exposed to hazards,
- The way the controls are operated does not eliminate having to access the hazard zone,
- To access controls, workers are forced to work in awkward bending postures,
- Controls descriptions and labels do not ensure an unambiguous identification of controls,
- Controls descriptions and labels fail to meet requirements concerning e.g. font size and operator’s native language,
- The available work manual does not clarify the meaning of symbols on press controls."
- Adam Górny. MATEC Web Conf. Volume 137 (2017). Ergonomic requirements for the operation of machines and technical equipment.
Comment#: 00002
Date: 2022-09-10
User: Radim
"Design from the operator's point of view. Talk with operators directly. Don't ask how to improve the HMI; most won't know, and some comments may lead you down the wrong path. Instead, ask operators what tasks they have to do, and find out what information they need in order to do those tasks easily and successfully. Watch them as they work."
- opto22.com; Building an HMI that works - New best practices of operator interface design (06/04/2021)
Comment#: 00003
Date: 2022-11-06
User: Radim
"The requirements analysis is the most important phase. There must be an operational concept of how the system will be used. Environmental conditions and user characteristics must be defined. Operational requirements consider how the users work and accomplish their jobs. A goal directed task analysis is used to identify high level goals (not the pre-conceived tasks to accomplish them), decisions, types of cognitive processes users employ, their need for interaction with others, and their situation awareness (SA) requirements. This can be determined through interviews and observation. The result is a system requirements document."
- Paul Gruhn. 66th Annual Instrumentation Symposium for the Process Industries January 27-29, 2011. Human Machine Interface (HMI) Design: The Good, The Bad, and The Ugly (and what makes them so) (Page 7).
Comment#: 00004
Date: 2022-11-29
User: Radim
"What matters isn't what the designer likes, what the standards are, or what's really in fashion - what matters is what makes the user's job easiest.
Therefore, it is extremely important to consult the application's interface with future users as often as possible."
Translated from:
- Petr Paleta. Computer Press (2003). Co programátory ve škole neučí (Page 295).
Comment#: 00005
Date: 2022-11-29
User: Radim
"Engage the end user. Probably the most important person in the whole process, yet many times we may be tempted to keep them at arm’s length; you should involve the customer actively. Have them give frequent feedback on the product for future improvement and development; software developers who respond quickly to customer feedback are generally more successful."
- 5 Tips for Developing an Effective Software Quality Testing and Assurance Culture.
- https://technofaq.org/posts/2017/04/5-tips-for-developing-an-effective-software-quality-testing-and-assurance-culture/
Comment#: 00006
Date: 2023-07-14
User: Radim
"A good interface is easy to learn, leads to faster reaction time, safer operations and higher productivity. You deserve a system that is intuitive - one that at a glance you can see what actions need to be taken and is easy to navigate."
- General Electric (2021). Modern HMI/SCADA Guidebook for Efficient Operations.
- https://www.ge.com/digital/lp/modern-hmiscada-guidebook-efficient-operations
Comment#: 00007
Date: 2023-08-10
User: Radim
"Because Cartesian robots can be mounted above or behind the machines they tend, they also allow users to run the machines manually when needed — for example, for a short run of a special size. This selective use is difficult with floor 6-axis robots, which can block access to the packaging machine."
- Bell Everman (2023). White Papers and Case Studies. Simple, Sophisticated Long-travel Automation.
- https://www.bell-everman.com/resources/case-studies/white-papers/simple-sophisticated-long-travel-automation
Comment#: 00008
Date: 2023-08-10
User: Radim
"The information that should be available on a graphical user interface (GUI) of a machine depends heavily on the type of machine and its application. However, here are some basic pieces of information that are often displayed on a GUI:
1. Status Information: The GUI should display important status information about the machine, such as whether it's powered on or operational, whether it has issues or error messages, and whether all systems are functioning properly.
2. Operational Parameters: Display the current operational parameters of the machine, such as speed, temperature, pressure, voltage, etc. This allows the user to monitor the machine's current state and make adjustments if needed.
3. Process Overview: If the machine is involved in an ongoing process (e.g., manufacturing, processing, analysis), relevant process data and steps should be displayed on the GUI. This helps the operator monitor the progress of the process and identify potential deviations.
4. Warnings and Error Messages: Display warnings or error messages if problems or critical situations arise. This enables the operator to react quickly and take appropriate actions.
5. User Interaction: Provide interfaces for user interaction, such as adjusting settings, changing parameters, or issuing commands. This includes buttons, dropdown menus, text fields, and other elements.
6. Historical Data: A history or log of past events and activities can be helpful for identifying trends, diagnosing errors, or making performance improvements.
7. Documentation and Help Material: Provide user manuals, help tutorials, or links to further information so that users can learn about operation, maintenance, and potential issue resolutions.
8. Visualizations: Depending on the application, charts, graphs, or visual representations of relevant data can be useful for recognizing relationships and trends more easily.
9. User Profiles and Settings: Allow users to create individual profiles and configure specific settings to match their workflow.
10. Safety Information: If the machine could potentially be hazardous, the GUI should display safety instructions, emergency stop buttons, or other safety mechanisms.
11. Contact Information and Support: Provide contact information for technical support or customer service in case users need assistance or support.
It's important to carefully design the GUI based on user needs and the type of machine to ensure a user-friendly and efficient experience."
- https://chat.openai.com (What information should be available in the machine's graphical user interface?)
Comment#: 00009
Date: 2024-07-03
User: Radim
Bear in mind that the operator sometimes operates the system in a panic and needs a short and fast route to the destination and a quick response from the system. The system must inform the operator of what has happened and what is expected of the operator.