It’s difficult to overstate the importance of a reliable human-machine interface (HMI). These devices are a crucial part of operating industrial equipment safely and efficiently, but not all offer equal benefits. Manufacturers will get more out of their HMIs by being selective when choosing one.

Making the most of an HMI in manufacturing requires careful setup and calibration, but it starts with opting for the right model. While no single HMI is ideal for every use case, organizations should look for a few key features.

1. An Easy-to-Understand UI

The most important thing to look for is a clear, easy-to-understand user interface (UI). How a screen looks and the way controls work may seem like aesthetic choices, but they have a significant impact on productivity.

When an HMI’s UI is not intuitive, operators could make mistakes. Even if they do not, they won’t be able to work efficiently if they must navigate through multiple screens or waste time searching for certain options. It’s also worth noting that this industry often requires more accessibility than others, as 35% of manufacturing workers have limited or no digital skills.

What constitutes an accessible UI depends on a company’s workforce. However, common elements include crisp, well-contrasted visuals, simple controls, informative labels and minimal submenus. It may help to look at user reviews for information about a product’s usability.

2. Compatibility With Existing Equipment

A human-machine interface must also be compatible with the machinery a manufacturer already uses. This begins with ensuring an HMI’s software and connectivity options work with the specific equipment model it will control. Refer to OEM product descriptions and user guides to verify interoperability before purchasing anything.

Compatibility concerns extend to other machinery, too, not just the infrastructure an HMI controls. One of the primary reasons to use an HMI is because they reduce operating costs by replacing hundreds of selectors, buttons and controls. Extending that functionality to additional systems takes those savings benefits further.

When an HMI connects to multiple machines, it can analyze more data to make informed automated decisions. Similarly, it consolidates a wider range of information into a single point of access, streamlining operations, so the greater the interoperability, the better.

3. IoT Connectivity

A similar key feature to look for is Internet of Things (IoT) functionality. IoT-enabled HMIs can wirelessly connect to other equipment within the factory, enabling greater automation and providing real-time data for added flexibility.

Increased visibility through IoT technologies can boost production efficiency by 20% in some cases. However, HMIs can only support such considerable gains if they use the same connectivity protocols as other IoT endpoints throughout the factory. Consequently, businesses must review their existing technologies to determine what standards their HMI should support.

Many factories use 5G cellular connections for their IoT systems, which offer the most speed and bandwidth. However, some may use Wi-Fi, Bluetooth or another protocol instead, in which case, it’s better to go with whatever platform they currently have.

4. AI Functionality

Artificial intelligence (AI) falls into a similar category. While AI is not a prerequisite for using an HMI in manufacturing, it does expand what a facility can do with this equipment.

AI features vary widely, but some are more helpful than others. Predictive maintenance is ideal, as it offers the most uptime and long-term cost reduction of any care strategy by minimizing both breakdowns and planned downtime. Other beneficial AI functions to look for include automatic reporting, real-time alerts, IoT data analysis and workflow automation.

In some cases, manufacturers may be able to deploy a custom AI solution after implementing an HMI. This strategy lets them capitalize on AI’s benefits when no built-in smart features are available. Still, an HMI with native AI capabilities will streamline the process, so these options are preferable.

5. Computing Performance

Human-machine interface selection must also cover a few practical considerations. The IT specs are a prime example, as they’re easy to overlook but critical to the device’s operation.

Any HMI needs enough computing power to manage the machine it will control as well as any additional software, such as IoT connectivity, AI models or security solutions. Organizations can get a better understanding of their needs by reviewing their existing IT infrastructure’s requirements. However, they must look for HMIs that exceed these minimums to leave room to scale up.

Specific computing factors include RAM, processing power and available storage space. Energy usage also deserves attention. Manufacturers purchase all but 15% of their electricity, so any equipment consuming less power will help reduce ongoing expenses.

6. Environmental Protections

Another practical HMI feature to look for is its physical safeguards. Industrial environments can be harsh, exposing devices to high temperatures, moisture and vibrations, so HMIs must be able to withstand any hazards they’ll face.

HMI OEMs should offer information on their products’ temperature resistance and waterproof ratings. When they don’t, manufacturers should reach out about these specifications to verify the equipment can endure its operating environment. Any limits should be well above the actual conditions an HMI will experience to leave room for emergencies.

Backup power supplies, system redundancy and similar emergency response features are also ideal. While they don’t reduce the likelihood of environmental damage, they can minimize its impact.

7. Cybersecurity Controls

Similarly, a modern human-machine interface needs built-in cybersecurity protections. Manufacturing has become the world’s most attacked industry, accounting for 25.7% of all cyberattacks in 2023. One of the key drivers of this trend is a rise in unsecured connected devices, so higher security standards are necessary.

HMIs must be compatible with an organization’s cybersecurity software of choice. Beyond that, businesses should look for controls like access restrictions — ideally multi-factor authentication, not just a password — data encryption and secure update protocols.

Some HMIs let manufacturers create multiple user profiles and assign unique access controls to each. Such functionality helps minimize insider threats, so it’s a good option if available.

Manufacturers Must Optimize Human-Machine Interfaces

The optimal next-generation HMI includes all seven of these features to some extent. While high-tech functions like IoT connectivity and AI may be less common, they’re growing and will become crucial as Industry 4.0 develops. Getting ahead of these trends now will ensure manufacturers get all they can out of their HMIs well into the future.