What is HMI development, and why is it trending now? 

The current industrial revolution — Industry 4.0, the Fourth Industrial Revolution, or 4IR — is certainly digital. It’s an era of connectivity, advanced analytics, automation, and manufacturing technologies that have been transforming businesses worldwide for years now. This wave of change has spread far beyond the manufacturing sector and holds unimaginable potential for operations and the future of production. 

In this context, we talk about Human Machine Interfaces (HMIs) — the ones connecting humans and machinery, leading to maximized efficiency and improved safety, and opening the possibilities never considered before. 

The definition of HMI 

A Human Machine Interface (HMI) connects a human interface module with the machine, device, or system to reach synergy and allow a user to interact with a device or mechanism, control it and monitor in the industrial processes. 

HMIs are usually used for data visualization, time or progress tracking, KPI overseeing, input/output monitoring, and other purposes, depending on the field of application and the type of software. Many of these systems work similarly to technologies we interact with in everyday life but on a much bigger scale. The most prominent HMI examples include built-in screens on machines, computer monitors, and tablets. 

In this article, we explain what HMI software is, what are the benefits and examples of these interfaces, and how Human Machine Interfaces are shaping the future of almost every field, from industrial to education. 

How it works? 

What is HMI software if not a prominent example of a bridging technology? HMI software meaning lies in connecting Programmable Logic Controllers (PLCs) and input/output sensors, enabling data exchange and providing users with actionable insights. Depending on their configuration, HMI screens can be tailored for basic tasks like monitoring and tracking or for advanced operations, such as controlling machine functions or optimizing production rates. 

HMIs centralize and digitize industrial processes and, therefore, play a critical role in improving overall operational efficiency. They can monitor and manage alarms and integrate with systems like supervisory control and data acquisition (SCADA), Enterprise resource planning (ERP), and manufacturing execution system (MES) — all from a single interface. HMI technology delivers real-time data directly from programmable logic controllers (PLCs) to an intuitive display, reducing reliance on archaic methods as well as the chance of errors and inefficiencies related to manual interventions.

What are the benefits of HMI software? 

Ease of use 

To embrace the difference in use, compare operating numerous buttons, levers, switches, dials, LED lights, and gauges to a touchscreen. The interface is intuitive and responsive, streamlined and user-friendly. It’s easy to learn and to operate, with much fewer chance of mistakes and mechanical errors. 

Increased productivity and efficiency 

The need to divide your attention into numerous control and monitoring functions dramatically decreases productivity. It’s physically and mentally overwhelming and requires extensive experience and constant coordination. With a single dashboard, the centralized platform eliminates the need to move across panels, boosting efficiency and reducing the number of errors, delays, and stressful situations. 

Improved employee safety 

Operating heavy machinery is not only a difficult but a potentially dangerous task. With HMI systems, operators can keep the distance from machines while not losing in productivity and keeping control. Moreover, while working from distance, they gain better visibility and monitor operations with higher precision.  Additionally, HMIs allow for remote visual inspections thanks to cameras that broadcast real-time images to the operator’s device. This means there is no longer a need for close physical proximity to potentially dangerous machinery.  

Increased reliability 

Machine reliability is the priority number one for industrial facilities, since this is the subject of efficiency and safety. With HMI, operators get access to the real-time data about machines operability and condition, collected by IoT sensors, gaining the possibility to spot animalities, fix issues, and prevent problematic or dramatic outcomes.  

Reduced costs 

All the advantages of HMI software collectively result in significant cost reductions. First and foremost, thanks to reduced maintenance expenses and faster staff training. Early spotting of issues lowers the cost of repairs and replacements, as well as downtime costs. Considering the ease of use and user-friendly interfaces, it’s not necessary to look for expensive, experienced operators – they can be trained in-house. 

High return on investment (ROI) 

A strong return on investment (ROI) makes HMI even more attractive for industrial facilities. The initial software implementation, HMI development, and mobile devices costs get quickly outweighed by the reduced operational costs and boost in productivity. Enhanced machine reliability, streamlined processes, and reduced training times — all together result in saving valuable resources and investment return.  

How HMI software enables smart manufacturing 

HMI software development is at the heart of the smart manufacturing revolution. It bridges the gap between technology output and human decision-making, opening the door for businesses to greater efficiency, flexibility, and scalability in their operations. Here is how it’s being done: 

1. Real-time monitoring and visualization 

With HMI software, operators gain access to well-structured, intuitive, data, collected in real-time and displayed in form of customized charts and maps. Thanks to such visualization, users gain a power of early spotting of issues, controlling productivity, and gaining valuable insights, necessary for business development and more informed decision making.    

2. Simplified control and interaction 

HMI systems offer more precise control and interactions with machines and automation systems. From adjusting setting to running diagnostics, fine-tuning operations and quickly interrupted issues, this simplified interactivity reflects in enhanced productivity and product or service quality.  

3. Easy and fast data integration  

One of the key characteristics of smart manufacturing is vast amount of data, generated at every stage of production. HMI software comes in handy when this data needs to be analyzed and integrated. Combined with the Industrial Internet of Things (IIoT), HMI delivers insights that operators can later use to optimize workflows, address issues, improve efficiency, adjust processes, and prevent potential mistakes. 

4. Remote monitoring and maintenance 

Most HMI systems include cloud connectivity that enables for a remote machine monitoring and control. Thanks to this, operators can run diagnostics ad address issues remotely, from any location, reacting quickly and supporting predictive maintenance strategies. This reflects in lower repair and downtime costs and uninterrupted production. 

How HMI shapes the future of smart manufacturing 

The next generation of HMI technology will redefine smart manufacturing. With AI, AR, IoT, and intuitive controls at its core, HMI will enhance productivity and empower operators to navigate the complexities of the industrial revolution. 

AI and ML 

These systems can analyse data in real time, define patterns, predict potential failures, recommend process optimizations, and autonomously adjust machine settings to reach better performance.  

Augmented Reality (AR) 

AR-enabled interfaces allow for overlaying digital information onto the physical environment, providing real-time guidance for troubleshooting, maintenance, and task control. Such an immersive experience allows operators to manage complex processes more precisely and efficiently, reducing the chance of errors. 

Industrial Internet of Things (IIoT)  

As the Industrial Internet of Things (IIoT) grows, HMI systems must handle larger and larger amounts of data generated by connected devices. To cope with this, HMIs integrate with IoT networks, enabling centralized control of multiple machines and processes. This integration simplifies operations in even the most complex industrial ecosystems. 

Voice and gesture controls 

Voice recognition and gesture control make HMI systems even more intuitive and accessible. Hands-free operation improves safety and efficiency, and voice control allows for even faster change-making. The development of these technologies will allow operators to execute commands quickly and accurately without manual interactions. 

Human Machine Interface examples 

While all HMIs serve a similar grand purpose, their designs and configurations vary, assisting in different operational needs. The following are examples of the most common types of HMI devices. 

Touchscreen HMIs 

While traditional interface panels with hardwired buttons have their uses, touchscreen HMI panels dominate when it comes to flexibility and user experience. These interfaces are so prevalent that they’ve become synonymous with HMI for many people. Touchscreen panels seamlessly integrate user input and display output, allowing designers to create custom screens tailored to specific tasks.  

Web HMIs 

Unlike traditional HMIs, Web HMIs rely on centralized servers for data storage and processing, eliminating the need for local hardware configurations. This setup reduces installation complexity and ensures that updates can be managed centrally, minimizing maintenance requirements.  

Headless HMIs 

Headless HMIs offer a unique solution for application modernization where a built-in screen is unnecessary or impractical. These devices omit the screen, instead transmitting video output via HDMI or network connections. This significantly reduces the size of the unit, which is incredibly beneficial in limited spaces.  

Industrial PCs 

While Industrial PCs may not fit the traditional definition of an HMI, they are worth mentioning for their versatility and power. These devices can perform all the functions of an HMI and much more. Industrial PCs allow for easy hardware upgrades, extending their lifespan and reducing long-term costs. Available in both panel-mounted and traditional configurations, Industrial PCs are well-suited for demanding applications that require robust performance and scalability. 

Fields and applications of HMI  

Thanks to its versatility, HMI technology gets adopted across the fields, bringing countless benefits and optimizing processes. The most common application of HMI technology is in monitoring industrial equipment and machinery, especially in factories and other industrial settings. Human Machine Interface systems display real-time data about different processes and allow operators to make fast and informed decisions.  

In the healthcare sector, HMIs are used in devices such as infusion pumps, patient monitors, and diagnostic equipment. These interfaces allow healthcare professionals to interact with complex systems, ensuring the most accurate patient care. HMIs also improve connectivity among devices and systems, enhancing efficiency and precision in healthcare. 

ATMs and other banking interfaces leverage HMI technology to facilitate secure financial transactions. Customers can use these systems to check balances, transfer funds, make withdrawals, and perform other banking operations quickly, securely, and conveniently. 

Touchscreen kiosks are a very common example of HMI application in public spaces. These interfaces provide information and services at transportation hubs, museums, retail locations, and office buildings. 

In educational environments, HMI technology powers tools like interactive whiteboards and tablets. These interfaces improve engagement and collaboration in classrooms, making learning experiences more engaging and accessible for students and teachers. 

With the advent of smart home technologies and building automation, HMIs are now leaders in managing heating, lighting, and security systems. Smartphone apps, touchscreens, and voice-controlled devices allow users to monitor and control entire buildings easily and remotely, improving energy efficiency and security and saving costs. 

In summary 

Industry 4.0 is racing, and HMI development is on the rise. With smart manufacturing and HMI industrial automation, those systems act as the crucial bridge between human operators and machinery. As industries continue to advance, HMI technology will evolve alongside emerging innovations such as AI, augmented reality, and IoT, driving further improvements in safety and productivity.  

The future of HMI promises even more intuitive and powerful tools, empowering industries to meet the demands of an increasingly automated and interconnected world. Contact us to discuss HMI development and define HMI that will make your system operations more efficient, convenient, and competitive.