How Human-Machine Interfaces Can Improve Productivity and Performance

Businesses of all sizes and across many sectors have discovered that human-machine interfaces allow them to streamline day-to-day processes. Usually referred to simply as HMI, human-machine interfaces have made an especially big impact in several industrial and manufacturing applications.

But what exactly is a human-machine interface and why do you need it for your company? In this article about the industrial benefits of HMIs, we examine not only what it is, but also how human-machine interfaces (HMI) improve the productivity and performance of your entire business.

What is Human-machine Interface (HMI)?

Many assume that an HMI is just another ordinary user interface, but this is not strictly true. Human-machine interfaces are similar to Graphical User Interfaces (GUI) in some ways, but they are distinct from each other and HMIs are most commonly used in industrial settings.

User interfaces often allow the control of multiple devices, but an HMI allows the user to control any single device through a dashboard or interface. In simple terms, an HMI allows humans to control particular machines.

HMIs also allow you to:

• Track production times
• Oversee your KPIs
• Monitor specific machine input and output metrics
• Identify patterns and trends

Using HMI in Industrial Applications to Improve Productivity and Performance

There are countless ways in which HMIs can enhance your business. We’ve grouped the benefits into these distinctive categories:

Minimized Risks and Delays

HMI solutions lessen the risk of workplace incidents and injuries among your human workforce by reducing human involvement in complex processes.

Workers can use machines to perform tasks that would otherwise be too complicated, repetitive, or dangerous for human hands. With greater automation, there’s a lower risk of injury. A combination of a human workforce and machinery with HMIs facilitation controls is the ultimate solution.

It reduces and, in some cases, eliminates the delays resulting from workplace incidents. That’s because it has a lower risk of error than manual workers alone. And with less downtime, it means you’ll keep on delivering your goods on time.

Reduced Energy Consumption and Operating Costs

HMI software is useful for analyzing other data too, such as the amount of energy each machine is using per day or process. This is vital information for your operations management. It’s one more way in which HMI solutions can improve your business’s efficiency.

By measuring and monitoring your machinery’s energy usage. HMIs give you up-to-date data that allow you to make changes where they’re needed. It will pinpoint where you need to reduce energy consumption.

You can then translate this data into action,  either by modifying your equipment or replacing it with low-energy alternatives. This, in turn, will lower your operating costs.

Amid the current trend toward more responsible manufacturing, this benefit stretches far beyond your own business. If you are looking for ways to implement more sustainable industrial practices, reducing your energy consumption is a great place to start.

Optimized Operational Efficiency

Workers can use HMIs to perform machine-related tasks with greater efficiency and above all, accuracy. With greater accuracy and efficiency, comes higher productivity.

You measure your operational efficiency through certain metrics, particularly your rates of production. This is true for any type of business. But how many products is your business manufacturing per day? And how quick and easy is it to keep track of the KPIs for your entire range of products?

Some HMIs offer the added benefit of targeted analytics for monitoring and measuring your production metrics and other key performance indicators (KPIs).

Mitigating Abnormal Situations with AI-Based HMI Solutions

You are more than likely already using PACs and PLC controls for your equipment and day-to-day processes. There are different approaches for integrating their data with HMIs. But when they’re closely integrated with HMIs, your diagnostics, and therefore your overall performance, will improve.

When any abnormal situation occurs production losses, off-spec and faulty products, equipment damage, or even a catastrophic incident become possible. Therefore, the first step in mitigating abnormal situations is the early detection of equipment anomalies and the diagnosis of faults.

AI-based HMI solutions integrated with your standard PLCs offer you higher execution speeds with better machine control and advanced diagnostics. What’s more, by combining the controller and interface into one device, you reduce the need for extra controller cabinet space and cabling.

Conclusion

Human-machine interfaces (HMI) are an invaluable aid to manufacturing and processing plants. They enhance productivity and efficiency, reduce workplace incidents, and can even optimize energy consumption. However, it all starts with the right automation and electrical controls.

At AEC, that’s what we do best. We’re a licensed ETL 508A panel building shop offering the automation and control components you need. Plus the support to keep your operations running smoothly. Contact us for more information about what we can do for your business.