Human-Machine Interfaces (HMIs) have become indispensable in modern industrial and commercial environments, bridging the gap between operators and electrical equipment. Whether it’s for monitoring, controlling, or analysing processes, HMIs offer intuitive access to complex systems.
The usability of these interfaces can be significantly hampered by design flaws. This article explores common HMI design mistakes and how they affect operational efficiency, with a focus on improving long-term usability and safety through well-informed deployment strategies.
Overcomplicating the User Interface
One of the most frequent mistakes in HMI design is the inclusion of too many elements or excessive data on a single screen. While it may seem beneficial to give operators all available information, cognitive overload can result in slower decision-making and increased error rates.
Employing a hierarchical screen layout can ensure that critical alarms and readings are immediately accessible, while less urgent information is kept on secondary screens. This strategy helps operators interact more efficiently with electrical devices and systems.
Inconsistent Visual Design
Visual consistency in HMI design plays a vital role in user learning and retention. Inconsistent use of colours, fonts, and symbols can confuse users, making it harder to interpret system states quickly. For instance, using red to indicate both a fault and an alert undermines the visual hierarchy and may delay an appropriate response.
Standardising colour codes and graphical representations not only aids usability but also ensures regulatory compliance in many industrial settings. A carefully designed HMI should maintain uniformity across all screens to support fast recognition and confident actions.
Neglecting User Feedback and Testing
Many HMIs are developed without sufficient input from the end-users, the operators themselves. This disconnect leads to designs that may technically function but fall short in real-world scenarios. Without iterative user testing, developers may overlook navigation challenges, unreadable fonts, or inefficient workflows.
Conducting usability tests during development phases and integrating user feedback mechanisms can substantially boost the usability and performance of the HMI system interface. Involving users early ensures the final product aligns closely with operational needs.
Ignoring Environmental and Contextual Factors
The environment in which an HMI is deployed affects how it is used. Glare from sunlight, the need for gloves, vibration, or exposure to dust and moisture can influence the usability of touch screens and other input methods. Designing an interface without considering these external variables can reduce both reliability and safety.
An effective HMI in industrial settings must accommodate these conditions by incorporating rugged touchscreens, tactile buttons, and adjustable display brightness where necessary.
Poor Alarm Management
A common issue in HMI systems is alarm flooding, a situation where too many alerts are triggered simultaneously, overwhelming the operator. This can cause critical alarms to be missed, delaying response times and escalating faults.
Implementing alarm prioritisation and suppression logic, along with clear visual cues, ensures that essential alerts receive immediate attention. A well-designed alarm system within an HMI platform also includes historical logs for analysis, aiding in continuous improvement.
Benefits of Collaborating with an Electrical Brand
Choosing to work with a well-established electrical brand offers significant advantages when developing or deploying an HMI. Such brands provide solid support frameworks, regular software updates, and long-term scalability options. A high-performing HMI for industrial operations must prioritise usability through thoughtful design, consistency, and user-driven development.
Avoiding common design mistakes can result in improved safety, faster operational workflows, and reduced training time for operators. Businesses can leverage high-quality engineering, expert guidance, and reliable support to successfully incorporate HMIs into their processes, ultimately enhancing efficiency and productivity.
