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How can you ensure HMI project management plan meets industrial safety standards?

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Human-machine interface (HMI) is a vital component of any control engineering project, as it allows operators to interact with and monitor the performance of complex systems. However, designing and implementing an effective HMI requires careful planning and adherence to industrial safety standards, which can vary depending on the application, environment, and regulations. In this article, you will learn how to ensure your HMI project management plan meets industrial safety standards by following these six steps:

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1 Define safety objectives

The first step is to define the safety objectives of your HMI project, which should align with the overall goals and requirements of the system you are controlling. Safety objectives can include reducing human error, preventing accidents, improving situational awareness, enhancing operator performance, and complying with relevant codes and norms. You should also identify the potential hazards and risks associated with your HMI, such as electrical shock, fire, explosion, or cyberattack, and how to mitigate them.

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Ben Scott, M.S.

Systems Engineer | Adjunct Professor | Ohio Cyber Reservist | Experienced Critical Infrastructure & OT/ICS Cybersecurity Architect | Championing a More Cyber Secure Ohio | Fortifying Ohio’s Critical Infrastructure
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HMI projects meeting industrial safety standards is paramount. Clearly define safety objectives tailored to the specific system & environment. This includes reducing human error, preventing accidents, & enhancing situational awareness. Compliance with relevant codes & standards is non-negotiable. Conduct a thorough risk assessment to identify potential hazards like electrical shocks or cyberattacks. Develop & implement mitigation strategies for identified risks. Regularly review & update your safety protocols to adapt to new threats or changes in regulations. Effective communication & ongoing training with your team are crucial to maintain a safety-first mindset throughout the project lifecycle.

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2 Choose appropriate HMI hardware and software

The next step is to choose the appropriate HMI hardware and software for your project, based on the safety objectives, system specifications, and environmental conditions. HMI hardware can include devices such as touchscreens, keyboards, mice, joysticks, buttons, lights, and speakers, which should be ergonomic, durable, and easy to use. HMI software can include platforms such as SCADA, DCS, PLC, or PC-based systems, which should be reliable, secure, and compatible with your system. You should also consider the communication protocols, data formats, and network architectures that will support your HMI.

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Ben Scott, M.S.

Systems Engineer | Adjunct Professor | Ohio Cyber Reservist | Experienced Critical Infrastructure & OT/ICS Cybersecurity Architect | Championing a More Cyber Secure Ohio | Fortifying Ohio’s Critical Infrastructure
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Choosing the right HMI hardware and software goes beyond technical specs. It's about ensuring user safety and system reliability when selecting devices. Consider the operational environment for high-dust, vibration, or hazardous locations requiring specialized equipment. For software, you should look beyond basic functionality and assess the support for future updates and scalability. Evaluate the ease of integration with existing systems and the flexibility to adapt to future expansions. The best choices are those that not only meet current requirements but also anticipate future needs, ensuring long-term safety, usability, and adaptability of your HMI system.

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3 Design user-friendly HMI interface

The third step is to design a user-friendly HMI interface that meets the safety objectives and the needs of the operators. A user-friendly HMI interface should follow the principles of human factors engineering, such as simplicity, clarity, consistency, feedback, and error prevention. You should also apply the best practices of HMI design, such as using appropriate colors, fonts, icons, graphics, layouts, menus, and navigation. Additionally, you should incorporate safety features such as alarms, warnings, indicators, and emergency stop buttons.

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4 Test and validate HMI functionality and usability

The fourth step is to test and validate your HMI functionality and usability, before and after deploying it in the field. Testing and validation can involve methods such as simulation, prototyping, debugging, verification, and user testing. The purpose of testing and validation is to ensure that your HMI performs as expected, meets the safety objectives and requirements, and provides a satisfactory user experience. You should also document and report any issues, errors, or feedback that arise during testing and validation.

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5 Train and educate HMI operators

The fifth step is to train and educate your HMI operators, who are responsible for using your HMI safely and effectively. Training and education can include topics such as HMI features, functions, operations, procedures, policies, and safety rules. You should also provide manuals, guides, tutorials, and support for your HMI operators. The goal of training and education is to increase the competence, confidence, and awareness of your HMI operators, and to reduce the likelihood of human error, misuse, or abuse.

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6 Monitor and maintain HMI performance and safety

The final step is to monitor and maintain your HMI performance and safety, throughout its lifecycle. Monitoring and maintenance can include activities such as data collection, analysis, evaluation, optimization, troubleshooting, updating, and repairing. You should also conduct regular audits, inspections, and reviews of your HMI, and implement corrective and preventive actions if needed. The aim of monitoring and maintenance is to ensure that your HMI continues to meet the safety objectives and standards, and to improve its quality and efficiency.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you ensure HMI project management plan meets industrial safety standards?

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1 Define safety objectives

2 Choose appropriate HMI hardware and software

3 Design user-friendly HMI interface

4 Test and validate HMI functionality and usability

5 Train and educate HMI operators

6 Monitor and maintain HMI performance and safety

7 Here’s what else to consider

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