6.2 Production Screens & HMI Standards

Data must be visible to be actionable. In a high-speed manufacturing environment, operators and managers do not have time to decode complex spreadsheets. Information radiators (screens) must answer the "Are we winning or losing?" question in less than 3 seconds. Design distinct visual layers for the Operator, the Line Lead, and the Plant Manager.

The Operator Terminal (The Cockpit)

This screen controls the work. It is not a dashboard; it is a tool. Clarity and speed are the only metrics that matter.

Design Rules

• The "3-Second Rule": The current state (Pass/Fail/Wait) must be readable from 2 meters away.
• Color Logic:
  • Green: Pass / Go.
  • Red: Fail / Stop.
  • Blue: Instruction / Info.
  • Yellow: Warning (e.g., Tool calibration expiring soon).
• Touch Targets: Minimum button size = 20mm x 20mm. Operators wear gloves; tiny "X" close buttons are forbidden.

Content Priority

1. Instruction (Top): "Scan Serial Number" or "Install Part X".
2. Feedback (Center): "PASS" (Big Green Text).
3. History (Bottom): Last 3 actions (for context).

The Line Board (The Scoreboard)

Located at the end of the aisle or overhead. Its audience is the Shift Lead and the team working on the line.

The " Pace" Metric

Do not just show "Total Produced." Show "Actual vs. Target."

• Target: 100 units (based on Takt Time).
• Actual: 90 units.
• Delta: -10 (Red).

Visual Hierarchy

• Primary (50% of Screen): Target vs. Actual (The Score).
• Secondary (25%): Current OEE / Efficiency %.
• Tertiary (25%): Active Andon Alerts (e.g., "Station 4: Material Low").

Pro-Tip: Use "Gamification." If the line is ahead of target, turn the background Green. If behind, turn it Red. The human brain reacts to color faster than numbers.

The Hallway Dashboard (The Executive View)

Located in the main corridor or canteen. Its audience is Management and Visitors. It aggregates the health of the entire facility.

Aggregation Logic

Do not show raw data from 50 machines. Show "Line Health."

• Line 1: Green (Running).
• Line 2: Red (Down - 15 mins).
• Line 3: Yellow (Changeover).

The "Top 3" Rule

Always display the "Top 3 Downtime Reasons" for the current shift. This prevents management from asking "Why are we down?" and focuses the conversation on "What are we doing about the Feeder Jam?"

Technical Constraints & Refresh Rates

A dashboard that lags is a lie.

Refresh Standards

• Operator Terminal: < 500ms (Immediate feedback).
• Line Board: < 10 seconds (Near real-time).
• Hallway Dashboard: < 60 seconds.

Hardware Durability

• Floor PCs: Fanless, sealed (IP65) for dust protection.
• Screens: Industrial grade (24/7 rating). Consumer TVs will burn out in 6 months due to static images.

Final Checklist

Category	Metric / Control	Threshold / Rule
Ergonomics	Touch Targets	Buttons ≥ 20mm x 20mm
Visuals	Color Coding	Green=Good, Red=Bad, Blue=Info
Latency	Operator Screen	Response time < 500ms
Content	Line Board	Must show "Actual vs. Target" (Delta)
Content	Hallway	Must show "Line Status" + "Top 3 Issues"
Hardware	Durability	IP-rated PCs on shop floor (No office desktops)
Validation	Legibility	Text readable from working distance (2m for Terminals)