Display flexibility lets operators focus on what’s important

Remote monitoring and connectivity allow operator-interfaces to reach beyond the past by leveraging both real-time performance and remote resources to improve future performance. Remote monitoring and connectivity is giving the operators on the front line the greatest access to resources that are required to change the reactive problem-solving narrative. This is accomplished by combining remote-processing capabilities and operator team collaboration.

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Production data can be logged and process signals shown in real time allowing operators both on-site and remotely to see the same metrics. This collaboration can create a synergy as operators can quickly gather internal subject matter experts for larger decisions without the lag of issue escalation, adding to the speed at which decisions are made on the shop floor.

Can you explain how software development has changed operator interfaces in manufacturing?

Thomas Kuckhoff, product manager—controllers, Omron Automation: Software evolution has allowed for a near infinite amount of flexibility for operator interfaces. Sensors can relay real-time fill levels of raw materials; thermocouples can display how processes are operating compared to standardized conditions; and stand-alone Andon lights can be integrated into condensed command centers.

By having this level of operator-interface customization, designers can focus operator attention on parameters that have the highest correlation to success, thus allowing operators to remove noise from the shop floor to create the highest-quality result based on process signals.

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In addition to the interface display flexibility is the sheer quality of these operator interfaces themselves. Being able to have the data on hand is only one aspect to making an effective interface; legibility is another. The quality of these interfaces allows for clear communication between operator and machine. The clearer the picture, the easier it is to act on the information displayed.

How do operator-interface technologies figure into digital-twin platform models being used by manufacturers?

Thomas Kuckhoff, product manager—controllers, Omron Automation: Digital-twin platforms become more complicated with the number of inputs, which can affect the output of the digital-twin model. Operator interfaces allow more data to be shown to operators while capturing more digital-twin-model independent-variable data in the process. This in turn refines digital-twin model accuracy but also displays the results from the model to the operator as the model becomes more refined through its respective life cycle.

A more robust digital-twin model combined with alignment of operator planning capability shifts reactive tasks to proactive tasks, which reduces downtime and increases overall equipment efficiency (OEE). Furthermore, any changes the operator makes to the machine is a learning opportunity for digital-twin models, which further creates a stronger model; it’s an ideal constructive cycle of learning to create.

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When will operator interfaces become IT-friendly enough that engineers are no longer required for installation and operation?

Thomas Kuckhoff, product manager—controllers, Omron Automation: This milestone is getting closer every day. While so much of machine programming is rooted in ladder logic, which is becoming ever more IT-friendly with drag-and-drop function blocks, operator interfaces have an inherent visual property.

Moving icons around the screen, adding gauges during machine operation and toggling between different screens are becoming more common, especially as these interface types are penetrating more facets of operator life, such as mobile devices, automotive displays and entertainment.

The value here is allowing the operator complete control of the machine to keep production consistent while exceeding quality goals. An example of this is how more operator-interface manufacturers are offering an increasing breadth of features which can be added with just a single tap of the screen.

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What future innovations will impact the use of operator-interface technology in manufacturing operations?

Thomas Kuckhoff, product manager—controllers, Omron Automation: Artificial intelligence (AI) has a real ability to impact the use of operator-interface technology. However, AI will have to demonstrate its value before complex algorithms are empowered to make major adjustments to machine performance based on digital twin models.

It’s natural that the first step to demonstrating robustness in design, while earning the trust of the plant floor, is to collaborate with operators. The operator interface is a natural location for this common ground to be built. Future innovations can turn the operator interface from a command center into a two-way conversation between operator and machine, both parties making recommendations based on data available to them.

Artificial intelligence will be able to analyze more data more quickly than the operator, which will give the operator the opportunity to make decisions on the plant floor more quickly and with greater confidence.