F R A U N H O F E R I N S T I T U T E F O R I N D U S T R I A L E N G I N E E R I N G I A O

E D I T O R S : D i e t e r s p a t H | a n e t t e W e i s b e c k e r

A U T H O R S : M a t t H i a s p e i s s n e r | c o r n e l i a H i p p

THE POTENTIAL OF HUMAN-MACHINE INTERACTION FOR THE EFFICIENT AND NETWORKED PRODUCTION OF TOMORROW

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fraunhofer verlag

1

Editors

Dieter Spath, Anette Weisbecker

Authors

Matthias Peissner, Cornel ia Hipp

THE POTENTIAL OFHUMAN-MACHINE INTERACTION FOR THE EFFICIENT AND NETWORKED PRODUCTION OF TOMORROW

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CONTENTS

1 ABSTRACT .......................................................................... 4

2 INTRODUCTION ................................................................... 6

2.1 Objective .................................................................................................................................. 6

2.2 Procedure ................................................................................................................................. 7

2.2.1 Experts involved ....................................................................................................................... 7

2.2.2 Preparation for the study: identifying issues ......................................................................... 8

2.2.3 Expert workshop: underlying conditions, outlining developments and issues ................... 8

2.2.4 Individual interviews: in-depth and detailed look at issues .................................................. 9

2.3 Structure of the study ............................................................................................................. 10

3 CONDITIONS OF THE PRODUCTION OF TOMORROW............ 12

3.1 Networked and intelligent production .................................................................................. 14

3.2 Transparent systems with real-time information .................................................................. 16

3.3 Flexible deployment of personnel ......................................................................................... 18

3.4 Employeequalification ........................................................................................................... 20

3.5 Standardized processes and traceability ............................................................................... 22

3.6 Safe and secure systems ......................................................................................................... 24

3.7 Product variety and short product cycles .............................................................................. 26

3.8 Internationalization................................................................................................................. 28

3.9 Sustainability ........................................................................................................................... 30

3.10 Mobile devices ......................................................................................................................... –32

3.11 Social media ............................................................................................................................. 34

3.12 New technologies for human-machine interaction ............................................................. 36

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4 CHALLENGES AND APPROACHES TO HUMAN-MACHINE INTERACTION IN PRODUCTION ........................................... 38

4.1 Design for humans .................................................................................................................. 38

4.1.1 Attractive design ...................................................................................................................... 38

4.1.2 Human-centered development processes .............................................................................. 40

4.1.3 More than a tool ...................................................................................................................... 42

4.2 The role of the human in networked production ................................................................. 47

4.2.1 The human as a sensor ............................................................................................................ 48

4.2.2 The human as a decision maker .............................................................................................. 50

4.2.3 The human as an instigator .................................................................................................... 52

4.3 Multimodal interaction .......................................................................................................... 56

4.4 Using the knowledge and intelligence of the system effectively ....................................... 58

4.4.1 Documentation and knowledge in the system ...................................................................... 58

4.4.2 System intelligence and automation hand-in-hand with the users ..................................... 60

4.5 One design – many variants ................................................................................................... 63

5 EXAMPLE PROJECTS ........................................................... 68

5.1 EPIK–Efficientuseofpersonnelthroughintelligentandadaptivecooperationand

information management in production ............................................................................... 69

5.2 KapaflexCy-Self-organizedcapacityflexibilityincyber-physicalsystems ........................ 72

6 SUMMARY AND INDEX OF GUIDELINES ............................. 74

6.1 Overview of requirements and guidelines for effective HMI design .................................. 76

6.2 Overview of requirements and guidelines for future-orientated HMI tools ...................... 77

6.2.1 SupportwithefficientHMIdevelopment .............................................................................. 77

6.2.2 Basics of intelligent and context-sensitive production control ............................................. 77

6.2.3 Interfaces and communication functionality ......................................................................... 77

6.2.4 Support for new technologies ................................................................................................ 77

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The human-machine interface (HMI) is becoming increasingly

important for controlling and monitoring industrial processes.

For manufacturing companies, HMIs provide an excellent

contribution to productivity, efficiency and employee

motivation. Further, machine and equipment manufacturers

guarantee themselves a competitive advantage through

ergonomic HMIs. Attractive design should express the ability

of the company to innovate, demonstrate the technical

excellence of the machine and create characteristic features.

Further, In addition to methodical and design-related know-

how, development tools and engineering environments are

also responsible for the efficient creation of high-quality HMIs.

An earlier publication1 by Fraunhofer IAO outlines the quality

characteristics required of such modern HMIs. This study

expands on these results, looking at current and future trends

in production and the effects on the requirements that will be

made of HMIs and HMI engineering tools in the future.

The most important changes to the underlying conditions in

the production of tomorrow can be summarized under the

term “Industry 4.0.“ Sensors and actuators will be widely

networked in the production environment and will allow

intelligent and immediate reaction to relevant results and

changes. In addition to increasing product diversity for the

conditions of mass production, they allow increased flexibility

of production processes, which consequently requires a work

force with flexible working hours and diverse qualifications.

Other changes concern the increasing significance of security

and traceability of processes, which will lead to increasing

standardization amongst other things. Trends which are

already constant, such as internationalization and

sustainability, will also create new impulses in the future.

Furthermore, current IT such as social media, mobile devices

and alternative interaction technologies, will influence and

extend the underlying conditions and design freedom for

modern HMI solutions.

ABSTRACT1

1 Bierkandt, J., Peissner, M., Hermann, F. & Hipp, C. (2011). Usability und Human-Machine Interfaces in der Produktion. Studie Qualitätsmerkmale für Entwicklungswerkzeuge. [Usability and Human-Machine Interfaces in Production. A Study of Quality Characteristics for Development Tools] Dieter Spath, Anette Weisbecker (Ed.). Fraunhofer Verlag. Download at: http://wiki.iao.fraunhofer.de/images/studien/usability- und-human-machine-interfaces-in-der-produktion.pdf

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In order to meet the upcoming challenges, there is a range of

requirements for HMI design and the HMI tools used: open

interfaces and compatibility with other IT systems is required in

order to be able to portray future networking scenarios in

efficient development processes. This also includes support

and meaningful use of methods of cooperation from Web 2.0

and new interaction technologies. Another issue is the

development in an interactive and user-orientated design

process that, in addition to efficient completion of tasks, also

includes emotional usage factors. Lastly, transparent and

accurate visualization is increasing in significance: both from

the monitoring of complex and sometimes abstract situations,

and also in order to offer effective support - especially in the

event of faults and exceptional situations. In doing so,

personalization and adaptation of the content, forms of

display and interaction mechanisms are of great interest.

In this study, requirements and guidelines for the design of

high-quality HMIs and the corresponding engineering tools are

formulated. They can serve as orientation in future HMI

projects, both for the design and development of attractive

HMIs and efficient engineering tools, as well as for the

selection of a suitable and future-proof HMI engineering

environment.

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HMIs are frequently created with special development tools.

These tools make development easier, for example through

classic SCADA3 functionalities and drivers for machine

controllers. On the other hand, they sometimes limit the HMI

design possibilities and their design determines the manner in

which designers go about the design and implementation of

the HMI. Therefore, the selection of an HMI development tool

frequently influences the work entailed in development and

the quality of the resultant HMI to a considerable degree.

Fraunhofer IAO has already described quality characteristics of

such tools and the development of high-quality HMIs in a

study published at the end of 20114. This study focuses on

recommendations based on current requirements and

underlying conditions.

However, most HMI projects have a lifecycle of more than ten

years. In addition, a longer-term decision in relation to

technology is often connected with the selection of a

development tool. Therefore, already-foreseeable

developments and future requirements should be taken into

account when selecting an HMI tool.

2.1 Objective

Easily operable and attractively interfaces between humans

and machines support the user in more than just learning and

operating a system. They also serve to positively influence

purchase decisions and to support a company‘s own brand

communication. Intuitive user interfaces can be communicated

to customers as a clear step in innovation and are a feature

that distinguishes a company from its competitors.

In doing so, the human-machine interface (HMI) in today‘s

production goes far beyond the mere control of machine

functions. It serves, in particular, for the visualization of

progress during processes, instructions for manual activities,

the administration of recipes and production programs and

support for various monitoring tasks through to integrated

management of everything that occurs in the whole

production process. HMIs should therefore be understood with

a broader definition, including all points of contact between

the different user groups and the IT systems in the whole

production environment. Appropriate to the complexity, user-

orientated development processes2 have now established

themselves as a fundamental basis for successful HMI design.

Based on the understanding of the user groups, their tasks

and the conditions under which they use the systems,

operational processes and interactive concepts are developed,

tested and iteratively optimized. Thus, a high quality of

operation and an optimal adaptation of the HMI to the

working processes can be achieved. In addition, the graphic

design of the user interface has become more important in

recent years. A primary objective is the efficient visualization of

important information and interrelationships. Furthermore, it is

a case of creating an aesthetic identity that is able to create

trust, a connection and a positive attitude.

2 See ISO/TC 159/SC 4 (2010). ISO 9241-210:2010 Ergonomics of human- system interaction - Part 210: Human-centered design for interactive systems.

3 SCADA: Supervisory Control and Data Acquisition

4 Bierkandt, J., Peissner, M., Hermann, F. & Hipp, C. (2011). Usability und Human-Machine Interfaces in der Produktion. Studie Qualitätsmerkmale für Entwicklungswerkzeuge. [Usability and Human-Machine Interfaces in Production. A Study of Quality Characteristics for Development Tools] Dieter Spath, Anette Weisbecker (Ed.). Fraunhofer Verlag.

INTRODUCTION2

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2.2 Procedure

The contents of this study were compiled on the basis of

workshops and interviews with relevant experts. In doing so,

the perspectives of production operation, IT and human-

machine interaction were covered. In order to combine the

future-orientated perspective of the study with a strong

relationship to practical application, experts from science and

practice were involved. The experts taking part provided, in

addition to experience within their own companies, valuable

input from cooperating companies, consulting projects and

larger training measures.

2.2.1 Experts involved

In addition to the authors, the following people made valuable

contributions to this study in workshops or individual

interviews (listed in alphabetical order):

Markus Ammann,

VOLLMER WERKE Maschinenfabrik GmbH

Mario Beck, KHS GmbH

Jan Becker, KHS GmbH

Wolfgang Buchkremer, ELOPAK GmbH

Dr.-Ing. Stefan Gerlach, Fraunhofer IAO

Lorenzo Guazelli, Danieli & C. Officine Meccaniche S.p.A.

Dr. Fabian Hermann, Fraunhofer IAO

Tobias Krause, Fraunhofer IAO

Doris Janssen, Fraunhofer IAO

Joachim Lentes, Fraunhofer IAO

Hagen Nürk, IST METZ GmbH

Friedrich Schneeberger, PAGO Fruchtsäfte GmbH

Univ.-Prof. Dr.-Ing. Dr.-Ing. E. h. Dr. h. c. Dieter Spath,

Institutsleiter Fraunhofer IAO

Phillip Werr, Ing. Punzenberger COPA-DATA GmbH

Therefore, the objective of this study is to consider the current

and future changes and developments in the production

environment and to analyze their potential effects on HMI

design. On this basis, the study identifies and explains:

Design recommendations and best-practice approaches

for effective, pioneering HMI design.

Requirements for future-proof HMI development tools.

This study therefore offers designers and developers of HMIs

an orientation aid for the strategic development of successful

design concepts. Furthermore, it supports companies in

selecting a suitable development tool, which equips them for

future developments. Additionally, the study offers

manufacturers and providers of development tools information

on trends and technologies which should be considered for

future developments and refinements.

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1. Introduction:

Presentation of the objectives and display of the prior

considerations, including the main issues.

2. Future issues and trends:

Brainstorming, presentations and discussion on the

following main questions:

What IT system properties will be important in the future

for efficient and human-orientated production?

What technologies and working methods will be

important in the future?

What does human work look like in the production of

tomorrow?

3. Strategies and objectives of the future

Brainstorming, presentations and discussions on the

following main questions:

How will the strategic objectives of manufacturing

companies change in the future? (for example, use of

resources, security, etc.)

How will the achievement of important objectives be

measured in the future? (key performance indicators)

What strategies will be used to achieve objectives

efficiently in the future?

4. Summary and conclusion

2.2.2 Preparation for the study:

Identifying subject areas

Initially, subject areas which were chosen were considered to

be the main issues the study should address.. In doing so,

experiences and findings from numerous research and

development project from Fraunhofer IAO were included.

Furthermore, foreseeable technical progress and trends were

included - in particular from the current Industry 4.0

discussion. The main issues identified in this first stage include:

Efficient process and cooperation models

Networking and integration beyond the limits of

equipment, company and technology

Ergonomic and attractive HMI design

Efficient system engineering

New technologies for human-machine interfaces

Mobility and flexibility

Individualization and context-adaptation

Automation and support for actions

2.2.3 Expert workshop: Underlying conditions,

developments and issues

A workshop was carried out for the second stage in order to

structure and finalize the scope that the study examines. The

workshop lasted four hours and was moderated by Cornelia

Hipp and Matthias Peissner (both Fraunhofer IAO). Five more

experts from the Fraunhofer IAO took part. In the process, the

areas of production management, a digital factory / digital

engineering and human-machine interaction were covered.

Actual project experiences and estimations of future

underlying conditions, developments and issues, came up in

the workshops from these different perspectives. The

workshop agenda comprised of the following items:

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The interview structure was based on the findings from the

expert workshops and comprised of the following topics:

1. Questions about the company and the interviewee‘s

personal role.

2. Open questions in relation to future developments that will

change the underlying conditions for efficient and human-

orientated production; including technologies, working

methods and the costs and efficiency of new

developments.

3. Questions in relation to opinions regarding trends and

future underlying conditions that were identified in the

expert workshops, for example, networking and

intelligence, transparency, the ability to work in real-time,

employee qualifications, standardization, security,

traceability, range of products, internationalization,

sustainability

4. Questions in relation to opinions with regard to production

support through new developments in human-machine

interaction that has been named in the expert workshops,

for example, user focus, design-for-error, mobile devices,

social web, new interaction technologies, adaptive and

individualized systems, visualization of information.

5. Open questions on other issues that appear important to

the interviewee and to prioritize the issues that have

already been discussed.

2.2.4 Individual interviews:

In-depth and detailed look at issues

The individual interviews were conducted in a semi-structured

manner: some over the phone, some in person. Depending on

the interviewee, the interviews were carried out so that the

interviewee could either, provide depth and detail on the

issues they were particularly familiar with, or could estimate

and clarify the extent the described trends and future

developments can be related to current and foreseeable

industrial practice.

2 . I N T R O D U C T I O N

1. Identifying issues

3. Individual interviews2. Expert workshop

Figure 1: Course of the study.

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Chapter 5 serves to illustrate the concepts presented in the

main Chapter 3 and 4. Two research projects are shown, EPIK

and KapaflexCy, which exemplify the contribution that

human-machine interaction can provide for networked and

efficient production in the future.

In addition to a summary, Chapter 6 contains an overview of

all identified requirements and formulated guidelines with

regard to the design and engineering of human-machine

interaction.

2.3 Structure of the study

The results of the study can be broken down into two main

areas:

Firstly, changes to the future underlying conditions of

production were identified, which entail new demands for the

design of human-machine interfaces. These changes must

therefore be taken into account for both HMI design and for

the selection of suitable HMI engineering tools. The most

important of these underlying conditions to be expected are

described in Chapter 3.

Secondly, Chapter 4 is dedicated to the human-machine

interface. On one hand, new challenges arise for HMI design

from the predictable underlying conditions. On the other

hand, there is the potential for more efficient production from

the current research activities in the field of human-computer

interaction from the future. Against this backdrop, guidelines

for effective HMI design and guidelines for the selection of

future-proof HMI engineering tools are formulated in

Chapter 4.

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2 . I N T R O D U C T I O N

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The underlying conditions of industrial production are

changing. Some of the developments that will have a

characteristic influence in the future already have an effect

today, or are at least already foreseeable. In an HMI project,

many influential decisions are made which remain in place for

several years. Therefore, when selecting a suitable HMI

engineering environment, and for fundamental HMI design

decisions, it is not just the current requirements that need to

be taken into account. A responsible and future-proof project

also includes a forecast of the underlying conditions and

requirements of the future. Such developments presented in

this study were compiled on the basis of meetings and

workshops with experts (cf. Section 2.3) and concentrate on

the underlying conditions that are seen in close conjunction

with the design, development and use of human-machine

interfaces5.

CONDITIONS OF THE PRODUCTION OF TOMORROW

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5 Another recent study by Fraunhofer IAO presents a detailed investigation of the future framework of production work:

Spath, D., Ganschar, O., Gerlach, S., Hämmerle, M., Krause, T. & Schlund, S. (2013). Produktionsarbeit der Zukunft – Industrie 4.0. Download unter http://www.iao.fraunhofer.de/images/iao-news/produktionsarbeit-der-zukunft.pdf

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Figure 2: Underlying conditions for the production of tomorrow

Networked and intelligent production

Transparent systems with real-time information

Flexible deployment of staff

New technologies for human-machine interactionSocial media

Employee qualification

Standardized processes and traceability

Product diversity and short product cycles

InternationalizationSustainability

Mobile devices

Secure systems

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3.1 Networked and intelligent production

In recent years, the fast and continued growth of technology

has resulted in increasingly better network solutions. Mobile

communication increases availability and enables new forms of

collaboration. These developments have also been deployed

within production; however, their potential is nowhere near

exhausted. For example, the social communication forms of

Web 2.0 are still used with a great degree of reservation.

Further, mobile internet usage for the intelligent connection

and networking of humans and machines can be expanded

upon considerably.

Comprehensive and intelligent networking provides great

potential for increasing efficiency in production. Information

from different sources can be combined and called upon from

any desired location. This way, comprehensive information

and important notices can be exchanged without losing time.

It is possible to react extremely quickly to short-term changes

and events. Needs-based, just-in-time, production can be

effectively supported as a result. In addition, service and

maintenance work can be conducted over long distances,

saving costs and time.

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As a result of the high degree of networking, very large

amounts of data will be available. However, it will be a major

challenge to extract information from this in a way that can be

used profitably to optimize production processes. One

example is the precise calculation of the current production

load and the optimization thereof.

Intelligent production systems will tackle these two aspects:

the networking and the meaningful evaluation of data. In

doing so, information from different sources, such as

messages about machine status and information that is

provided to employees via their mobile devices, will be

integrated. Furthermore, an intelligent factory offers effective

mechanisms to be able to react appropriately to the

information recorded. Additionally, pre-defined and self-

learning information can permanently and automatically

ensure a high degree of efficiency by linking certain sensor

results to regulating mechanisms.

Networking is carried out at different levels:

Sites in globalized production are networked. As a result

of this, it is possible to compare production processes.

Many companies already connect their branches around

the world in this way.

Machines provide information on their own status and

thus allow monitoring via a central control room.

Networking also makes it possible to control the

machines from any desired location and to trigger

appropriate actions. Individual machines have already

been triggered to start remote maintenance in order to

ensure high-quality support.

Superordinate production systems are networked with

their subcomponents, which sometimes come from

different manufacturers.

Employees are increasingly equipped with mobile and

networked devices. Consequently, they become more

easily contactable and have the ability to retrieve

information when outside of the workplace. This

introduces numerous scenarios for increased efficiency.

Interfaces to external software for production and

business processes such as ERP or document

management systems offer possibilities for two-way

communication with important data resources.

3 . C O N D I T I O N S O F T H E P R O D U C T I O N O F T O M O R R OW

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3.2 Transparent systems with real-time information

Today, we have comprehensive solutions for monitoring

production parameters. Information on the course of

production, the states of machines, faults and the localization

of these, as well as important key performance indicators

(such as the degree of utilization) can be displayed to the user

and provided graphically in various ways. With the increasing

level of automation and ever-more complex processes,

effective information visualization is now a fundamental

requirement for transparent production systems. Permanent

traceability of what the system is doing becomes especially

important if significant processes no longer have any physical

or directly-perceivable equivalence as a result of the increasing

use of software or through new technologies such as

biotechnology or nanotechnology6. Then there are completely

new challenges for clear and easy-to-understand

visualization.

In addition to appropriate graphical provision of information,

the time components also have a significant influence on the

transparency of the system. As a result of higher computer

processing power and transfer speeds, as well as new

interfaces, much information can now be displayed in real

time. For example, the status of machines and equipment, as

well as aggregated performance figures can be sent and

displayed live.

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Personalized display of information:

As a result of the increasing extent and complexity of the

information available, personalized selection and

preparation of the information is becoming increasingly

important. Not all information is as meaningful to all

employees. Management is interested in different

performance figures to those that interest operators.

Furthermore, the informational requirements of individual

people change over time and depend on the situation

and task. Therefore, optimum provision of layers for

different users and usage situations is important.

Evaluation and further processing:

In order to be able to use the real-time data recorded

reasonably for optimization of the overall system, intelligent

automated functions are often required. These functions

integrate and interpret data and then deduce the

appropriate reaction accordingly. The development of such

mechanisms is sometimes cost-intensive and very

demanding. Furthermore, human decision-makers do not

always want to give up their influence completely.

Therefore, design approaches are required that allow

efficient co-existence of automated mechanisms and the

monitoring and optimization of these by human operators.

The advantages of transparent systems with real-time

information include, the following aspects:

Quicker reactions:

Reaction times to changes in production systems can be

reduced significantly, because the necessary information

is available immediately. This is a significant advantage in

the areas of troubleshooting and fault rectification in

particular.

Targeted measures:

Fine-granular intervention is possible as a result of the

exact identification of the sources of the problem.

Traceability:

The processes are comprehensible and traceable for the

employees. This makes the monitoring of production

easier.

Increased dynamics:

The data available can be used immediately for other

calculations and short-term optimizations. For example,

shift plans or resource planning can be created and

updated in real time. However, optimum use of real-time

systems also entails particular requirements.

Requirements for employees:

Quick and appropriate reactions by employees require

certain abilities and subject knowledge, which may

possibly be only acquirable through additional

qualifications.

3 . C O N D I T I O N S O F T H E P R O D U C T I O N O F T O M O R R OW

6 Other examples include high speeds that cannot be recorded without aids (such as drinks bottle filling with 50,000bottles per hour) or the monitoring of quality parameters that cannot be perceived by humans (such as during the painting of cars).

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3.3 Flexible deployment of personnel

There is already a strong demand for the flexible deployment

of personnel. As a result of current developments, it is possible

to conclude that this demand will increase further.

The volumes have become highly volatile. Reliable

forecasts for staffing requirements are thus barely possible.

The extreme fluctuations in the economy lead to further

insecurity, which makes longer term planning difficult.

Many companies react to this with by increasing their

number of temporary workers. As a result of this, the

proportion of core employees, who are employed on a full-

time basis, is reduced. Further, the percentage of temporary

employees not only increases, but fluctuates.

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In addition, employees will need to be more flexible in regards

to their main activities at work:

Wider scope of duties – broader qualifications

As a result of the increased degree of automation and

the increased networking (cf. Section 3.1) the current

dominant 1:1 assignment of employee to machine will be

loosened. In the future, employees will be able to react

more flexibly to production events and execute very

different tasks. This increases the diversity of an

individual’s range of tasks. At the same time, a broad re-

qualification for different tasks and areas of activities is

important (cf. next section).

Ready on call

In the future, ad-hoc work and short-term reactions to

critical events will be required. Networking and real-time

capability of systems, as well as being equipped with

mobile devices, provides the technical requirements for

this – including for outside normal working hours.

In-service whilst mobile

Certain tasks can also be completed when outside the

workplace and from home.

On the other hand, new ideas for moreflexibleworking

time models were discussed, in order to react to the

fluctuating order situation. This included:

The conscious creation of comprehensive time accounts

in months with high sales with a subsequent reduction of

time in phases with weak sales.

More flexible changes of weekly working times and part-

time and full-time employment that can also reflect

changes in the personal prioritization of free time and

salary in different stages of life.

Lifetime accounts that are kept regardless of the

company are also retained if a person changes employer.

3 . C O N D I T I O N S O F T H E P R O D U C T I O N O F T O M O R R OW

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3.4 Employeequalifications

In industries with a high degree of automation, a development

towards fewer employees with growing responsibilities and

tasks can be observed. There are increasing requirements

forqualifications, for machine operators in particular. They

must be familiar with different machines and manufacturing

processes, have knowledge of complete production lines and

processes and be able to react quickly and competently to

various problems. In addition, the tasks can be more complex,

as information from several networked facilities must be taken

into account at the same time.

In addition to this development, a current trend of increased

use of low-qualified and even unqualified employees is

reported, most of whom are from low-income regions. In such

situations, especially low production costs often occur as a

result of a low degree of automation and high usage of

lowly-qualifiedpersonnel. Furthermore, the product launch

time (time to market) can often be minimized if complex

automation solutions are not developed and it is possible to

start with manual production immediately.

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In addition to ergonomic user interfaces, individually-tailored

qualificationmeasureswill increasingly be required to cover

the need for highly-qualified and flexibly-deployable staff.

Current and future developments that result in an increasing

requirement for further education include:

Increasingly shorter product lifecycles and need for

flexibility. As a result, employees are frequently confronted

with new developments.

An increase in the fluctuation of staff as a result of

reactions to short-term or seasonal events which are

implemented with the help of temporary employees.

These new employees must often be trained quickly (cf.

3.3).

The increasing heterogeneity of the user groups (cf. 3.8).

Different circles of people must master the same

production processes.

The lack of specialist employees in Western countries

which will progressively mean that employers are

confronted with the challenge of training new employees

themselves and preparing for company-specific

requirements in a targeted way.

The demographic shift which will change the supply of

workers. Older employees will also need to become

familiar with new technologies and machines.

Ergo, the following requirements are characteristic of human-

machine interfaces in the future:

High Usability

User interfaces must be designed in such a way that they

can also be understood and easily operated by employees

with little experience, no qualification and a low level of

education

Personalization

User interfaces must allow employees with different

competencies and levels of education to use the system

equally effectively. This requirement favors the use of

mechanisms to personalize user interfaces (cf. Section

4.5).

Keep knowledge in the system

User interfaces should contain the knowledge required

for carrying out tasks which are important to the user.

This will enable less-experienced employees to complete

these tasks and will support frequent change between

different areas of operations. A structured user guide and

context-sensitive systems can make a significant

contribution to this.

Instructiveness

User interfaces must be instructional: i.e. they must

support the user in acquiring new skills and offer

incentives for them to gain more qualifications - even in

regards to the demographic shift.

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3.5 Standardized processes and traceability

The traceability of actual production processes is becoming

more important. In certain industries, such as the

pharmaceutical and medical technology industries, there are

legal obligations for completely traceable documentation. In

other areas, companies use it to protect themselves against

claims for damages and complaints, as they can precisely

prove that quality management requirements have been

complied with. Depending on the industry, it is possible to

grant access to more than ten years of production data.

In conjunction with the vision of a paperless factory, there is

thus a need for saving and archiving of very large amounts

of data. Firstly, the technical challenges of saving, recovery

and archiving in formats that will remain for the long-term is

entailed. Secondly, there are also significant requirements for

the design of human-machine interfaces; the content that is

searched for must be able to be found easily and the data

structures must be shown in a comprehensible way on the

user interface.

23

In addition to the traceability, the potential for quality

assurance and continued optimization also go in favor of

increased documentation of the actual processes:

With the monitoring and checking of the production

processes, adherence to requirements can be checked.

The documentation can support a process of continuous

improvement. The data collated can be subsequently used

for analysis in order to identify issues for optimization. The

behavior and corresponding results of exceptional

situations, that have not yet been fully mastered, can be

used to create regularity and to develop precisely-adapted

procedural regulations.

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A significant trend for safeguarding an invariable quality of

manufacturing is the standardization of processes.

Approaches to normalize procedures have already been used for

years with “lean production.“ With this, all manufacturing

stages in which the employees are involved are broken down

into clearly divided partial stages. This way, errors which occur

due to a lack of process specification can be avoided.

Furthermore, standardized processes allow a high degree of

user guidance through human-machine systems, in order to be

able to also efficiently include less qualified people in the

process. There are also certain advantages for the traceability. In

highly standardized processes, it can also be sufficient to

document deviations from the standard, such as manual

intervention in the event of a fault.

In addition to the standardization of processes within the

company, increased standardization of the communication

interfaces between machines, equipment and superordinate

systems, such as SCADA and MES, is expected. Existing

standards, such as the Weihenstephan Standard in the food

industry, for example, have a high degree of acceptance in the

marketplace. However, in many cases they do not go far

enough to ensure comprehensive networking beyond system

limits.

24

3.6 Safe and secure systems

Safety will be more important in production processes of the

future.

Occupational safety is the first issue here. For industrial

companies, the well-being of their employees is important not

only for ethical reasons, but also economic reasons. Sickness

and downtimes are risks that must be minimized in these

times of increasing volatility of orders in particular. In the

Western world, there is already a high, legally-regulated level

of safety that is likely to also increase in the interests of the

company in light of the lack of specialist personnel. However,

it is also foreseeable that workplace safety will increase in

importance in developing countries and corresponding

solutions and technologies will be increasingly requested.

Ultimately, in a safe and safeguarded environment, a sense of

the company valuing its own employees is also expressed. This

can lead to increased employee satisfaction, motivation and

thus increased productivity.

25

In addition to the security risks the use of IT brings, nowadays, it

is increasingly recognized that the progress of information

technology also provides enormous potential for increasing the

security of production. Problems and faults can be recognized at

an early stage, sometimes even predicted or avoided before

they occur. Furthermore, interactive systems can support the

analysisandeffectiverectificationoffaults (cf. Section

4.2.3).

Furthermore, secure production systems are important for

avoiding production downtime. Unexpected incidents that

entail larger repairs are connected to a high degree of

economic losses and endanger the ever-prominent success

indicator of the OEE (overall equipment efficiency). Production

downtime or limitations can also entail organizational and

logistical problems. This is particularly the case if production

planning is calculated on a time-critical basis (just-in-time

production).

As a result of the growing use of IT systems, IT security is also

becoming more important. A secure and reliable IT

infrastructure is becoming increasingly important in order to

avoid problems and downtime and to guarantee optimum

planning capabilities. A significant challenge results from the

increasing opening of the production networks. Whilst these

were previously completely self-sufficient and insular in the

past, they are becoming more open to external networks via

the internet. The major advantages that are consequently

created, for the use of mobile devices for networked and fast

communication between different companies and sites, are

faced with new security risks. A secure IT infrastructure

therefore includes security against attacks from outside,

system stability and options to restore previous states in the

event of system failures.

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3.7 Product variety and short product cycles

Nowadays there are hardly any large production series that

have run for years in the same form. This trend, of low

quantities and small lots, will probably increase in coming

years. One reason for this is the massive shortening of product

lifecycles. Another is the increasing variety of products as part

of the megatrends of diversity and individualization. The

significant challenge of this development is the economical

allocation of engineering resources in terms of costs and time

to increasingly smaller production series. Approaches which

will gain significance include:

27

Setting parameters instead of programming

Engineering tools in the future will mostly be measured

by their extent to provide and support complex and

dynamic production processes efficiently. With the

motto, “set parameters instead of programming,” a

promising approach is now being taken that allows a

basic program to be quickly and easily adapted by

entering case-specific parameters. Thus, a wide range of

different variants can be covered. Such creation of a

human-machine interface appropriate to the task is still a

challenge.

Efficient tooling up

With low quantities and frequent changing of lots, the

minimization of the time and effort involved in tooling up

will become a certain strategic objective. Automated

solutions that combine lot and recipe management and

minimize manual retooling can provide great efficiency

advantages and eliminate sources of errors. Otherwise,

the system should be equipped so that the required

activities for retooling can be carried out easily, quickly

and without errors. Instructive user interfaces can offer

effective assistance with this.

Modularization

As a result of the mass customization approach, attempts

are being made to transfer the advantages of cheap mass

production to individualized products. The

implementation is frequently based on a basic product

appropriate for the masses, with certain properties that

can be adapted to create numerous variants. Other

approaches of mass customization are based on building

block approaches for the modular creation of an

individual product

Simpler manufacturing technologies

Simplification of multi-level production processes will also

be used to reduce the time and effort involved in

engineering. Generative manufacturing processes, which

are currently mainly used for rapid prototyping, offer

excellent potential for small quantities in particular.

Hybrid automation solutions

In order to be able to keep up with the fast-paced

product cycle, it will be necessary to speed up the

planning process considerably. Hybrid automation models

are becoming increasingly relevant to minimize the time

between construction and production, while not losing

the advantages of automation. Following an extremely

short planning phase, primarily manual production can

be started. Then, increased automation and further

refinements can be progressively implemented.

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3.8 Internationalization

Globalization characterizes the current and future conditions

of production decisively – through the following three aspects

in particular:

International markets

We are moving in global markets. German and European

products are sold throughout the world and must assert

themselves against products from all parts of the world.

Domestic production also requires the purchase and supply

of raw materials and components from various countries.

International cooperation and networks

Nowadays, products are frequently produced in

international collaborative networks. In doing so, the

production sites involved are often distributed throughout

different continents and consequently, members of the

different teams come from different cultures.

Remote service and maintenance

The machines and equipment of leading manufacturers are

distributed to the whole world. However, direct contact and

immediate reactions are required in order to rectify

problems on a short term basis or to provide planned

maintenance and servicing.

29

Glocalization

A successful HMI design for international sales markets and

user groups requires strategic positioning between global

design and localization. In doing so, the components of the

user interface that should be designed with a uniform

appearance; those that should be adapted to different

language areas and cultures must be clarified.

Remote access

Remote access to significant information and functions of a

production system and individual machines will be a central

requirement for economic systems in the future. In

particular the possibility to properly carry out servicing and

maintenance that requires a high degree of technical

competence from long distances will gain in significance in

the future. In addition to a corresponding technical

infrastructure, an increasing number of companies are

recognizing the necessary requirements in HMI design,

which includes, appropriate interactive functions,

transparent visualization systems and effective

communication possibilities.

For the design of effective human-machine systems, the

following consequences and requirements arise:

International HMI design

Optimum HMI design solutions require a deep understanding

of the user, their mental models, ways of working, and

requirements. In doing so, it is usually not sufficient to only

take the meanings of colors that differ between cultures into

account. Cultural standards also influence the interpretation

of icons and symbols, as well as the understanding of

processes and cooperation, working methods and learning

habits.

International HMI engineering

Software solutions for the creation and administration of

human-machine interfaces should meet all requirements for

secure and efficient internationalization. In doing so, it is not

only important that HMIs are possible with different fonts,

language versions, reading directions etc., but also that the

engineering process for provision of more localized variants is

optimally supported. An example of this could be intelligent

mechanisms for the administration of different language

versions, which take into account factors such as different

text lengths on buttons.

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3.9 Sustainability

“Sustainability” is often discussed in public life, politics and in

companies. The primary reasons for this are the fast-growing

world population, the high use of diminishing natural resources

and the build-up of waste products. Even today, production

systems are expected to take environmental perspectives into

account, just as much as social and economic perspectives.

Thus, a further increase in the significance of resources and

environmentally-friendly technology is clearly evident.

For companies, the question of the extent to which they can

achieve positive effects for their image and purchase decisions

by stressing sustainability arises. This applies for sustainability

when manufacturing the product as well as its subsequent use

by the customers.

Sustainable production processes can save costs. Often we

think of manufacturing processes that save energy and preserve

resources. In doing so, numerous solutions can be found such

as direct recycling of heat emitted, the minimization of water

consumption, the construction of lightweight machines and

the optimization of energy efficiency. This topic thus contains

much potential for pricing that is less than that of the

competition.

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3 . U N D E R LY I N G C O N D I T I O N S O F T H E P R O D U C T I O N O F T O M O R R OW

When designing future-orientated human-machine interfaces,

the following requirements arise:

Transparency

A fundamental requirement for the optimization will be

making the load of relevant resources transparent to

both employees and decision makers in an appropriate

way. In doing so, care should be taken to ensure that the

information is presented in a way which can be easily

interpreted and be classified as meaningful by the target

group.

Motivation

Furthermore, it is important to be able to persuade the

employee towards the company objectives and to

influence their behavior in this direction. Design

approaches of “persuasive design”7 and “gamified

design”8 can make an important contribution in

changing attitudes and behavior through new insights

and positive incentives (cf. Section 4.1.3).

The reduction of transit routes is an important aspect. Firstly,

long transit routes between globally-distributed transport routes

of a production creation and usage chain are looked at

increasingly critically. Secondly, there are discussions as to

whether the immense daily commuter traffic can be minimized,

by relocating more production sites to cities. The term “urban

production” is also interesting with regard to the constant

growth of cities. For the first time in the history of mankind,

more people live in cities than in the country. Cities therefore

require more resources and produce more waste. This waste

could be interesting as a mine of resources for production in the

future. Industrial heat could also be used to heat residential

living quarters.

The issue is sometimes handled in conjunction with other

corporate social responsibility issues, such as health

management, ergonomics and occupational safety. The

latter considers sustainability of the company’s own human

resources and diverts the focus to the question of how the

health of the employees, performance and employee motivation

can be ensured on a long term basis. In addition to simple

measures of health protection such as the reduction of stored

chemicals not being sealed and the use of separate storage

rooms, health-promoting programs are increasingly offered to

employees.

7 Persuasive design aims to change the attitudes and behavior of the user in a positive way. In doing so, no pressure is exerted, but persuasion and social influence is used

8 Gamified design describes the application of design characteristics and mechanisms that are typical for interactive computer games and other areas such as work equipment, business applications, consumer products, etc.

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Furthermore, mobile phones can also be used to include

employees in the handling of faults or problems that do not

occur at production sites. This allows more flexible and

efficient reactions to critical events and increases the

productivity of the workforce. Certain activities can

therefore be carried out from home, which promotes more

flexible working times and an improved work-life balance.

Location-related services can also be implemented through the

localization of mobile devices. Thus the information and functions

offered can be adapted depending on the location of the user, in

order to implement limitations on machine operation when out

of sight. Or information that is particularly relevant to the current

location can automatically be displayed, for example detailed

information on machines that are in close proximity. If reasonable

measures have been taken, it is possible to minimize the time and

effort needed for interaction on mobile devices.

Finally, the location of the mobile device can also be used for the

management of the whole production process. For example,

when delegating urgent tasks, the current location of the

employees can be taken into account, in order to minimize

walking distances and reaction times. In addition, when

approaching a machine, the user of the device detected can

automatically be logged in as the user on the machine, in order

to implement personal documentation and rights management

reliably and efficiently.

3.10 Mobile devices

Mobile devices are now very widespread. According to the

German federal association BITKOM, as at April 16, 2012,

around 88% of all Germans (over the age of 14) use a mobile

phone and one in three Germans already own a smartphone9.

The sales figures of mobile phones worldwide have also

increased considerably in the past years10. As a result of browser-

based remote applications and the installation of special apps,

smartphones and tablets can now be used in many ways. Apps

are already used in the area of production too. As a result of the

expansion of mobile phone networks and wireless LAN, as well

as improved data transmission rates, such services that require a

good data connection can now be used when on the move.

In a networked production environment (cf. Section 3.1) mobile

devices can be used to access different information and systems

from anywhere. This results in a certain location-

independence, i.e. locational disconnection of the user from

the place where their actions have an effect:

In particular for large-sized production areas, there is the

advantage that information from different floors can be

made available at any desired location. So employees who

are responsible for several machines or entire production

lines can always have a complete overview . They can also

receive notifications when an action is required and look-up

detail information about any desired equipment or process

from anywhere. This results in, interesting scenarios for an

ad-hoc documentation of notable items and quick

reactions to real-time information on faults or any other

urgent need for action (cf. Section 3.2).

33

There are special requirements when designing human-

machine interfaces for mobile devices, including the

following:

The relatively small displays on most mobile devices require

careful selection of the information to be displayed. It is

often necessary to subdivide larger blocks of information

into smaller units and to offer navigation paths appropriate

to the tasks between the sub-stages.

Entry of data is also laborious with mobile devices and

should be limited to inputs that are absolutely necessary.

Frequently-entered values can be offered as pre-selection.

Search functions can shorten long navigation paths and are

particularly effective if you have mastered autocomplete

and offer frequently-used options directly as a pre-

selection. In addition, alternative input technologies (such

as voice) offer great potential.

Mobile communication still unfortunately suffers from

relatively low data transfer speeds. Communication

concepts that, for example, only require a punctual server

connection and otherwise work locally and save data on

the mobile device can compensate for this at least in part.

The development of user interfaces that are usable on

several different platforms is still a great challenge – both

from the perspective of the technologies and efficient

engineering as well as the usability (cf. Section 4.5). In

addition, the user in the production hall, should experience

a seamless transition between the HMIs of mobile devices

and that of machine panels or PCs.

If mobile devices are used for warnings and error messages,

it must be taken into consideration that they are not always

noticed visibly by the user. In this case, the use of acoustic

signals and vibration is recommended (cf. Section 4.3).

In light of the increasing prevalence of apps, smartphones and

tablets, it is conceivable that in the future machine-orientated

functions can also be made usable via mobile devices. Where

possible, no separate control panel will be required in certain

cases and the whole human-machine interface can - with the

exception of the emergency-off switch and a few mechanical

controls – be transferred to mobile devices.

Because mobile devices are primarily used by individual users as

a personal device, they offer the best conditions for

individualization of user interfaces. For example, the

extensiveness and depth of detail of the information displayed

can be adapted to the level of knowledge and needs of the

respective user.

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9 BITKOM Bundesverband Informationswirtschaft, Telekommunikation und neue Medien e.V.: [German Federal Association for the Information Economy and New Media] Jeder Dritte hat ein Smartphone [Every Third Person Has a Smartphone] , Berlin, 2012, http://www. bitkom.org/de/presse/8477_71854.aspx (accessed on September 12, 2012)

10 Statista GmbH: Absatz von Mobiltelefonen weltweit in den Jahren 2005 bis 2011 (in Millionen Stück), [Sales of Mobile Phones Worldwide in the Years 2005 to 2011 (in Millions)] http://de.statista.com/statistik/daten/studie/192704/umfrage/absatz-von-mobiltelefonen-weltweit-seit-2005/ (accessed on September 12, 2012)

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3.11 Social media

The corporate in-house use of social media in German

companies is still very low. At the end of 2011 / start of 2012,

fewer than 10% of companies stated that they use social

media in product development (7%), knowledge management

(7%) or production (3%)11.

However, in the future, the potential of social media, such as

wikis and blogs, for productive activities in the value chain is

expected to be significantly exploited. This provides attractive

opportunities to actively include employees in the processes of

production planning and control, knowledge management,

and continuous improvement. Areas where social media can

potentially be used include:

35

The continuous improvement process (CIP) can also be

supported by social media. Accessibility via permanently-

used human-machine interfaces minimizes

communication barriers, allowing people to provide their

own suggestions and proposals for improvement. As a

result of the immediate visibility of the proposals and

corresponding possibilities for all employees to leave

comments, creativity, motivation and sense of teamwork

are reinforced.

In comparison to the technical implementation of such

approaches, the organizational questions, in relation to

integration within existing processes and structures, is certainly

the greater challenge. Exemplary problem areas include quality

assurance and the editing of user-generated content, the

specialist, organizational and social competence of different

user groups and the effective reuse of knowledge gleaned.

Employees can make text contributions or audio and

video clips to help other employees, for example when

working on difficult tasks or when rectifying problems

that have been solved successfully. This can lead to

significant increases in the efficiency of help systems and

knowledge management – both on the part of the

user and also for those who create help systems and

documentation.

Sensor information that constitutes the basis for

intelligent production processes can be supplemented,

corrected or validated by employees. In addition,

employees can contribute information on production

status, material and personnel resources and machine

status. This allows reliable production planning and

control, which can be optimized in real time. Fixed

assignments of working processes to individual

employees can be replaced or supplemented by means of

collaborative negotiation mechanisms, in order to use the

knowledge of all employees for optimum use of capacity.

With blogs, current events and information can be

published. News can be positioned prominently, like on a

pin board and subscribers to the blog would be informed

automatically. For example, important messages for

people on the next shift can be passed on.

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11 BITKOM Bundesverband Informationswirtschaft, Telekommunikation und neue Medien e.V.: [German Federal Association for the Information Economy and New Media] Social Media in deutschen Unternehmen [Social Media in German Companies] Berlin, 2012, https://www.bitkom.org/files/documents/Social_Media_in_deutschen_Unternehmen. pdf (accessed on 21 February, 2013)

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3.12 New technologies for human-machine interaction

Technical progress, in particular for recognition technologies,

allows new forms of human-machine interaction that goes far

beyond pressing buttons and using the mouse. In addition to

multi-touch and touch gestures, voice applications are already

in use. Promising technologies with a longer perspective

include eye tracking, gaze control, tangible and touch

interfaces and gesture recognition in open spaces. New

interaction technologies offer the potential for companies to

distinguish themselves by means of innovative operation and

can – if they are used correctly – increase efficiency and also

be enjoyable to use.

However, in order for new methods of operation to be

successful, there must be usage scenarios where they provide

genuine added value and can be integrated into a coherent

and intuitive interaction design. The potential for new

interaction technologies that can be forecasted today includes:

37

The merging of physical and virtual (IT) reality

Augmented reality (AR) offers massive potential for

efficient support for actions. Usually the view is

augmented through a special set of glasses or the camera

of a mobile device. This way, information on equipment

or items being worked on can be displayed, or correct

positioning and movements of the user’s hand can be

demonstrated1. In the area of employee training, virtual

reality (VR) approaches are especially interesting. With

simulated practice scenarios employees can train for

working procedures in a realistic setting without fear of

making mistakes with serious consequences.

Interaction mechanisms that are based on recognition

technology are generally prone to errors. It is therefore

important that such inputs are always accompanied with clear

feedback so that the user immediately notices any recognition

error and can correct this. Furthermore, with machine

operation in particular, there are frequently functions that

must be carried out completely reliably and directly in order to

avoid breakdowns or accidents. In these cases, the operating

mechanisms used must be safe and resistant to errors.

3 . C O N D I T I O N S O F T H E P R O D U C T I O N O F T O M O R R OW

12 See example: http://av.dfki.de/images/stories/Video/AR_Handbook-2013_v3.mp4

Touchless interaction

In some areas touchless HMI interaction is of great

interest. Firstly, for hygienic reasons, be it because very

dirty fingers should not touch the touch screen or other

controls or because in a clean room environment, any

unnecessary control object should be avoided and

capacitive touch displays can often not be operated

when wearing gloves. Secondly, touch screen interaction

offers the possibility to carry out manual activities that

require both hands at the same time, whilst different

information is called up or even entered on the screen.

These advantages can be implemented by methods

including eye control, voice control and (sometimes)

gesture control.

More efficient user inputs

With conventional input using menus and touch or a

mouse, the possible information stages are generally

limited to the objects that are currently displayed. As a

result of this, interaction sequences, to get to a simple

function, are often longer as they require navigation

through several submenus. With multi-touch and touch

gestures, special additional functions can be made

available by means of one single user interaction. Voice

detection also offers the basic possibility of calling up all

functions of a system at any time with a single command.

More impressive is the gain in efficiency that can be

achieved for comprehensive text inputs that can be

simply dictated or recorded via voice.

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4.1 Design for humans

4.1.1 Attractive design

A growing number of companies recognize the strategic

significance of an attractive human-machine interface. In

production too, interaction design is increasingly understood

to be an important distinguishing tool. In addition to the pure

functionality, reliability and precision of the technical products,

the design is increasingly moving into the consciousness of

decision makers.

With a high-quality HMI design, three strategic objectives in

particular can be combined:

Communication

The HMI is the (inter)face to the customer and the user. It

decisively determines the user’s experience with the

product and thus the impression that the customer

receives. An HMI that was developed with little care can

communicate a negative image and quality. However, if

this HMI communication is used in a targeted way, the

customer’s and user’s attitudes towards the product can

be positively influenced. At the start of an HMI design,

the properties and particular features that are to be

transported by the HMI and the design methods used for

this should therefore be clarified.

The following outline of challenges and approaches to

solutions identifies requirements and best practice approaches

for effective HMI design and outlines which specific properties

of an HMI engineering environment will be important for

successful HMI projects in the future. For better orientation,

these two types of requirements will be characterized with the

following graphic signs:

Future underlying conditions (see Chapter 3) place new and

amended requirements on the design of the human-machine

interfaces in production. In addition, in recent years,

procedures and approaches for solutions from the field of

human-computer interaction have developed that offer great

potential for efficient and successful interaction in the

production environment. Some of these approaches have

already established themselves in other fields and can – if

adapted accordingly – be transferred to application in industry.

One example is the targeted emphasis of emotional usage

factors, as they are sometimes used in the internet or in the

automotive industry. Other approaches such as multimodal

interaction or adaptive usage interfaces must, in contrast,

orientate themselves more towards current research results.

CHALLENGES AND APPROACHES TO HUMAN-MACHINE INTERACTION IN PRODUCTION

4

Requirements and best-practice

approaches for HMI design

Requirements for future-proof HMI

engineering tools

39

CHALLENGES AND APPROACHES TO HUMAN-MACHINE INTERACTION IN PRODUCTION

13 Bierkandt, J., Peissner, M., Hermann, F. & Hipp, C. (2011). Usability und Human-Machine Interfaces in der Produktion. Studie Qualitätsmerkmale für Entwicklungswerkzeuge. [Usability and Human-Machine Interfaces in Production. A Study of Quality Characteristics for Development Tools] Dieter Spath, Anette Weisbecker (Ed.). Fraunhofer Verlag.

Innovation

HMI design not only helps to communicate and clarify

technical innovations to the user, but also has enormous

potential for innovation. For example, data that has been

present in the system for a long time can have completely

new value for the user as a result of being presented in a

new visualized form. Furthermore, HMI sketches and HMI

prototypes make technical possibilities and processes

directly perceivable. HMI illustrations are thus an excellent

means to exchange experiences with decision makers,

customers and users and to develop ideas for innovative

approaches.

Productivity

The productivity of employees can be increased

considerably with user interfaces that feature a high level

of usability. An intuitive illustration requires quick

orientation and error-free operation. More efficient

interaction avoids unnecessary steps and speeds up the

processes. As a result, the time and effort for training

and support is reduced and many tasks can be completed

by different colleagues without specialization or longer

periods of induction (cf. flexible deployment of

personnel, Section 3.3). For HMI engineering tools,

usability plays a dual role: Firstly, it must allow the

creation of high-quality HMIs, and secondly, the time and

effort spent on engineering is reduced if the development

environment itself meets high usability requirements.

HMI Tool 1

Import f rom profess iona l

graphic s programs

HMI development tools should allow users to easily

import graphics from specialized graphics programs. Such

professional programs enable superior graphics creation,

allowing for the development of more attractive HMIs.

Attractive and easy-to-use HMIs place particular requirements

on the tools with which they are developed. The most

important of these requirements are already summarized in

the study entitled “Usability and Human-Machine Interfaces in

Production”1 from Fraunhofer IAO.

40

However, most HMI development tools are still not in a

position to effectively support such a process.

4.1.2 Human-centered development processes

Good design never serves its own purpose; instead it always

supports certain objectives and addresses actual target groups

in the process. The finding that people, in particular the user,

should be placed at the center of all considerations when

developing a new system is a significant insight of many

industrial companies in recent years.

The ISO standard 9241-210 “Human-centered design for

interactive systems”14 describes principles and procedures for

human-centered technical development (see Figure 3). In

addition to the active inclusion of future users into all phases

of development, this standard envisages intuitive refinement

and optimization of design drafts in order to ultimately

achieve a high probability of an efficiently-usable product

design.

Figure 3: Human-centered design process (ISO 9241-210)

HMI Des ign 1

HMI des ign in a human-centered

des ign process

User-orientated design processes have proven themselves

to be extremely successful and practical. Therefore,

companies that value high-quality HMI design are already

orientating their design and development processes in

accordance with the principles of ISO 9241-210.

14 ISO/TC 159/SC 4 (2010). ISO 9241-210:2010 Ergonomics of human-system interaction -- Part 210: Human-centered design for interactive systems.

Plan the human-centeredactivities

Understand and specifythe context of use

Specify the userrequirements

Evaluate: Sati�esrequirements?

Yes No

Produce design solutions

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HMI Tool 2

Support for i terat ive des ign processes

Advanced HMI development tools should support

iterative design processes; thus, not only supporting the

realization of the end product, but also the development

and refinement of varying draft versions. Features of such

development tools include:

Information architecture and navigation structure, as

well as support for the definition of the central objects

and views

Creation of grid and layout templates that can be

used throughout all screen views

Wireframes and the linking of these to storyboards

(for example via status diagrams or flow charts)

Simple creation of interactive prototypes (click

dummies) on the basis of wireframes (for example for

early user tests)

Graphically-created user interface elements that can

be kept as generic modules in a library in order to

be able to reference them in different interaction

scenarios

Function for identifying, commenting and tracking

15 CIF: Common Industry Format. In a current ISO initiative, documentation formats for the (interim) results of a user centered design process are defined. ISO 25060 offers the framework for this: ISO/IEC TR 25060:2010 Systems and software engineering -- Systems and software product Quality Requirements and Evaluation (SQuaRE) -- Common Industry Format (CIF) for usability: General framework for usability-related information

proposals for improvement (such as from user tests) and

open and completed design decisions in the draft design

Tailor-made views and processing possibilities for the

different roles in a design process, such as developers,

designers, product managers, user researchers. Also, the

possibility of these people working on simultaneously on

a project

Support in the creation of documentation such as a user

interface specification

A support function for requirements management in

the design process could be helpful. This could be, for

example, covered by a reference of design drafts for

requirements that are maintained and administered in a

software tool. A somewhat more laborious alternative

would be the management of requirements in the

HMI environment directly. For example, the HMI

environment could support CIF15 compliant report

formats for requirements specifications or usage context

descriptions

4 . C H A L L E N G E S A N D A P P R O A C H E S T O H U M A N - M A C H I N E

I N T E R A C T I O N I N P R O D U C T I O N

42

Sense of wellbeing and lasting productivity through

usability

In addition to efforts to improve work-life balance, the

ergonomics of software solutions in particular should be

mentioned. The keyword “usability” summarizes the

properties of an interactive system that allows an

effective, efficient and satisfactory completion of working

tasks. As a result of a clear display of information and

easy operation, the productivity of human work can be

increased.

4.1.3 More than a tool

A major task for current HMIs is supporting the completion of

defined working tasks as efficiently as possible. In addition to

this pure “tool” function, HMIs can also have further effects

on corporate strategy. A fundamental distinction between

three levels of effect of HMIs can be made (see Figure 4):

Occupational safety through design-for-error

A good interaction design relates completely

systematically to error situations such as system errors

(breakdowns) and operator errors (human error). Any

eventuality that could lead to unwanted results should be

considered during the design phase. Design strategies to

avoid the detection and rectification of errors are central

characteristics of a safe and economical system (cf.

Section 4.2.3).

Figure 4: Levels of employee orientation and their equivalent in HMI design

Engagement&

Identification

Wellbeing&

Lasting Productivity

Occupational Safety&

Avoidance of Down TimeDesign for Error

Usability

User Experience

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User experience (UX) is now considered one of the major

factors for the success of a product. Whilst conventional

usability engineering is primarily aimed at successful

completion of working tasks and primarily concentrates on the

avoidance of problems and the resultant stress, user

experience considers issues through a holistic perspective:

UX considers the human experience holistically and thus

includes emotions.

UX is interested in the subjective perception of the user.

Objective facts take a backseat to subjective impressions.

UX considers positive experiences in particular.

In contrast to classic usability perspectives, which are instead

aimed at avoiding negatives, positive feelings, such as

excitement, joy and trust, are the focus.

Identification and motivation by user experience

Most innovations are barely conceivable without a

commitment that goes beyond the basic mandatory

workload of an employee. A continuous improvement

plan that accepts proposals for improvement from all

colleagues is a good example. However, a fundamental

requirement for this is an employee’s ability to identify

with their company and its objectives. Such employee

commitment can be promoted considerably by the design

of the human-machine systems. The keyword “user

experience” has been summarized in recent years to

mean the properties of an HMI that offer more than the

avoidance of operating problems. User experience means

positive emotions when using technical systems. This

frequently requires interesting characteristics and

attractive design.

Figure 5: User experience encourages employee commitment and creativity(Harbich & Hassenzahl, 2011).

Usability

UX

Execute

Expand

Engage

Evolve

Individual working stages can be carried out without impairment.

Finding new ways to achieve the overridingobjective in an unconventional way.

Motivation to engage yourself beyond the actual tasks.

Working objectives are achieved by means of a different type of execution.

4 . C H A L L E N G E S A N D A P P R O A C H E S T O H U M A N - M A C H I N E

I N T E R A C T I O N I N P R O D U C T I O N

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User experience can be achieved through extended

functionality to directed graphical provision. For example,

feedback on personal or group-related performance

parameters (such as “How much has already been produced in

this shift?”) can lead to experiences that relate to competence.

Approaches to rectifying errors or knowledge management

that build on the mechanisms of social media and

communities can address needs for popularity amongst

colleagues, connectedness (we help each other in difficult

situations) or influence (my proposal for a solution could be

included in the general process regulations for the whole

company)