VZ01 - How to Improve Plant

Operations Through Better HMI Graphics

Dan Zinzow • User Experience Designer

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Agenda

1 2 3 4
Intro Problems Solutions References

5
Packet
“Design is so simple, that is
why it is so complicated”
Paul Rand

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BP Amoco, Texas City (2005)
BP Amoco, Texas City (2005)
What is HMI?
User interface to monitor and control machine or system

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Problems
Information overload
• Large amounts of process data

• Ineffective displays

• Inappropriate use of graphics

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Human cognitive limitations
• Memory

• Attention Environment:
• Vision Input

Rehearsal
Attention Short-term Long-term
Sensory
Memory Retrieval Memory
Memory

Rehearsal Loop
Recall
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Texaco Pembroke (1994)

Well designed HMI

• Prevent shutdowns
• Improve safety
• Improve efficiency
Texaco Pembroke (1994)

Shutdowns and accidents, costly Well-designed HMI

• Injuries • Help prevent shutdowns
• Downtime and accidents
• Productivity • Help improve safety
• Insurance • Help increase efficiency

High ROI for well-designed HMI

Solutions
Better HMI

how
what
where
who

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 The user
• Roles, functions, expertise
• Focus on primary user
• Don’t forget others

• Goals and Tasks

• Observation + interviews
• Identify information + context

• Human limitations + capabilities

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Mental model

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Persona

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The environment
• Technology
• Screen type

• Equipment
• PPE

• Workstation
• Cabinet
• Audience

• Conditions
• Lighting
• Noise

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The strategy
Building upon findings from User and Environment

• Documentation

• Organization

• Layout

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Documentation

Philosophy
Best practices
Lifecycle
Style Guide
Key principles
All aspects covered
Highly detailed
New standards
Rockwell Automation Process HMI Style Guide (PROCES-WP023A-EN-P)

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Documentation

Philosophy
Best practices
Lifecycle
Style Guide
Key principles
All aspects covered
Highly detailed
New standards
Rockwell Automation Process HMI Style Guide (PROCES-WP023A-EN-P)

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Organization

• User’s Goals + Tasks

• Match User’s Mental Model

• Related Information Together

• Navigation Paradigm

• Progressive Disclosure (4 levels)

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Hierarchy

Level 1 Overview Display

Provide an overview of the
operator’s entire span of
responsibility.

Level 2
Operator’s primary operating
Process Unit Control Display display. Normal operations, routine
changes and monitoring.

Level 3
Non-routine operations. Provide
Process Unit Detail Display sufficient information to facilitate
process diagnostics.

Interlocks, Diagnostics, Help

Level 4 Process Unit Support Display and Documentation. Usually
faceplates or popups.

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Multi-Level, Multi-View Displays

Shown on a big More detailed

screen monitor all Level 1 display. Used for
the time. higher level control.

Level 2 Level 2

Level 3 Level 3 Level 3 Level 3 Level 3 Level 3

Level 4 Level 4 Level 4

Traditional P&ID Style
Diagnostic level or task- display used to operate
oriented display. Used to show every aspect of the process.
troubleshooting data. (optional)
 Level 1

• Assimilate Quickly

• Performance Indication
Obvious

• Highlights Key Info

• High-level

• Easy Access to
More Detail

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 Level 2

• Main Displays

• Info + Control

• Create First

• User’s Mental Model

• Easy Access to
Other Displays

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 Level 3

• Detailed View of:

• Sub-Units
• Equipment
• Components

• Troubleshooting

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Level 4
More Detail

Procedures

Pop-ups

Faceplates

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Navigation

Main

Related

Consistency

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Don’t do this… Instead, do this…

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Layout

Not P&IDs

Match Mental
Model

Remove What’s
Unnecessary

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Layout

Not P&IDs

Match Mental
Model

Remove What’s
Unnecessary

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Don’t do this… Instead, do this…

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The Tactics
Execution based on your strategy

• Limitations

• Tools

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Limitations

Environment:
Input

Rehearsal
Attention Short-term Long-term
Sensory
Memory Retrieval Memory
Memory

Rehearsal Loop
Recall

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908230498230497509872349857109821340987098
742305987109821340987209875098172309487213
098470982498098234590829809817230948712349
802498067456870983473460983434580938094533
463085489009737098139158248813198349801398
52340968702943867092
908230498230497509872349857109821340987098
742305987109821340987209875098172309487213
098470982498098234590829809817230948712349
802498067456870983473460983434580938094533
463085489009737098139158248813198349801398
52340968702943867092
908230498230497509872349857109821340987098
742305987109821340987209875098172309487213
098470982498098234590829809817230948712349
802498067456870983473460983434580938094533
463085489209737098139158248812198349801398
52340968702943867092
Pre-attentive attributes

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Pre-attentive attributes, continued

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 “You know you have reached
perfection of design not when you
have nothing more to add, but when
you have nothing more to take away”
Antoine de Saint-Exupéry

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The Tools

• Element

• Location

• Size

• Label

• Color

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“Data is not information”
Cliff Stoll

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Element
Information is data… in context… made useful

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Temp Acidity DHEA
Blood Pressure CSF Cholesterol
Temp Blood Pressure Cholesterol
Vertical gauge
User-defined name
Tag name
Scale
Alarm threshold Tick marks

Normal operating range

Current value
Setpoint

Numeric display
Engineering unit

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 Trend Name Units
Setpoint High limit Current value

Scale

Pen marker

Grid

Time span
Low limit
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Sparkline

Name
Value
High limit

Current value
Units Setpoint Low limit

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Icons

Urgent High Medium Low

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Objects

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Location

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Location

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Location

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Location

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Size

Primary

Secondary

Tertiary

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Label

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Color

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Color

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Color

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AI: Opacity

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AI: Aesthetics

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Color

Don’t do this… Instead, do this…

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Color
• Element
• Location
• Size
• Label
• Color

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• Element
• Location
• Size
• Label
• Color

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PlantPAx® FactoryTalk® View SE

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Studio 5000 View Designer®

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FactoryTalk® Cloud

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References
References
• ISA 101, Human-Machine Interfaces
• ASM Consortium Guidelines – ISBN 978-1514203859
• Effective Console Operator HMI Design: Second Edition (2015)
• PROCES-WP016A-EN-E. Human Machine Interfaces for Distributed Control Systems:
Creating and Maintaining an Effective User Environment with Efficient Graphics.
• PROCES-WP023A-EN-P. Rockwell Automation Process HMI Style Guide.
• “High Performance HMI Handbook,” Hollifield et al
• “Information Dashboard Design,” Stephen Few
• American Fuel & Petrochemical Manufacturers AM-15-07
• Operator Situation Awareness & Delivering ASM-Compliant High
Performance HMIs: Failure Modes and Success Factors
• Rockwell Automation® Library of Process Objects
• Available from the Rockwell Automation® Knowledgebase
• KBAid 62682 – Rockwell Automation Library of Process Objects
• Rockwell Automation TechED™ 2016 Presentation: TS03: The Operator-Centered HMI: A Practical Approach
• Rockwell Automation TechED™ 2019 Presentation: VZ02: How to Improve Plant Operations Through Better HMI Graphics
Packet
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P75Zz7o5yi73XExfL5K-/view?usp=sharing
Thank you
www.rockwellautomation.com