4.3 Dashboards & Shopfloor Displays

Data must be visible to be actionable. In a high-speed manufacturing environment, operators and managers do not have time to decode"analyze" complexcharts. spreadsheets.They Informationneed radiatorsinstant (screens)situational awareness.

The 3-Second Rule

Requirement: A viewer standing 5 meters away must answerbe theable "Areto we winning or losing?" question in less than 3 seconds. Design distinct visual layers for the Operator,understand the Line Lead,Status (Running/Down) and the Plant Manager.

The Operator TerminalPerformance (TheWinning/Losing) Cockpit)

within 3 seconds.

ThisConstraint: screen controlsIf the work.dashboard It is notrequires a dashboard;mouse click or scroll to find critical data, it is a tool.failure.

Clarity

Standard Layout A: The Operator Cockpit (Station Level)

Displayed on the HMI or Tablet directly at the work center.

Focus: Immediate Execution & Feedback.

Zone	Widget / Block	Metric
Top Left	The Identity	Current WO, Part Number, Description.
Top Right	The Score	Actual Qty / Target Qty (for this hour).
Center	The Instruction	Current Step Image + Active Alert (e.g., "Check Orientation").
Bottom	The Pulse	Last Cycle Time vs. Target Cycle Time.

Logic:

• If Cycle Time > Target → Then Background turns Yellow.
• If Machine Error → Then Full Screen Overlay Red with Error Code.

Standard Layout B: The Digital Andon (Line Level)

Displayed on Large Format TVs (55"+) mounted overhead. Visible to the entire cell.

Focus: Flow, Pace, and speed are the only metrics that matter.Bottlenecks.

The Hourly Output Board (The "Pace" Block)

A simplified table showing hour-by-hour performance.

• DesignRow: RulesHour (08:00, 09:00...)
• Col 1: Target (Plan)
• Col 2: Actual (Produced)
• Col 3: Delta (+/-)
• Visual Rule: If Delta is Negative → Then Text is Red.

The Line State (The "Status" Block)

• The "3-Second Rule":Visual: TheMassive currentbackground statecolor (Pass/Fail/Wait) must be readable from 2 meters away.change.
• Green: Running (Speed > 90%).
• Yellow: Micro-stop / Slow (Speed < 90%).
• Red: Down (Duration > 5 mins).
• Blue: Material Call / Support Needed.

The Pareto (The "Fix It" Block)

• Widget: Top 3 Downtime Reasons (Current Shift).
• Widget: Top 3 Defect Types (Current Shift).
• Goal: Tells the Line Lead exactly what to attack next.

Data Visualization Rules

Adhere to strict UI/UX standards to prevent cognitive load.

• Color Logic:Hygiene:
  • Green: PassGood / Go.Running / On Target.
  • Red: FailBad / Stop.Stopped / Below Target.
  • Blue:Grey/Black: InstructionIdle / Info.No Schedule.
  • Yellow:Rule: WarningNever use Red for "Company Branding." Red is reserved for "Alarm."
• Font Size:
  • KPIs: Min 150pt (e.g.Readable from 10m).
  • Labels: Min 40pt.
• Animations:
  • Prohibited: Scrolling tickers (Marquees). They distract peripheral vision.
  • Allowed: Blinking (Red Only) for "Line Down" states.

Refresh Rates & Latency

Old data is dangerous. Define strict refresh intervals based on data type.

Data Type	Max Latency	Mechanism
Machine State	< 2 Seconds	WebSockets / MQTT Push
Production Count	< 5 Seconds	Event Trigger
OEE / KPI Calc	< 1 Minute	SQL Aggregation Job
Shift Report	1 Hour	Periodic Snapshot

Drift Control:

• Watchdog: The dashboard must ping the server every 10 seconds.
• If Connection Lost → Then Display "Offline / Stale Data" overlay clearly. Do not show frozen numbers.

Hardware & Ownership

A TV on the wall is an orphan unless owned.

• Hardware:
  • Use Commercial Displays (rated 16/7 or 24/7), Toolnot calibrationConsumer expiringTVs.
  • No soon)Peripherals: No mouse/keyboard attached. Use "Kiosk Mode."
  • PC: Micro-PC (NUC/Raspberry Pi) mounted behind the screen (VESA mount).
• TouchRACI Targets:Ownership:
  • IT: MinimumOwns buttonthe sizeHardware, =Network, 20mmand x 20mm. Operators wear gloves; tiny "X" close buttons are forbidden.

  Content Priority

  1. InstructionOS (Top): "Scan Serial Number" or "Install Part X"Patching).
  2. FeedbackMES (Center):Team: "PASS"Owns (Bigthe GreenLayout, Text).Data Source, and Logic.
  3. HistoryProduction (Bottom):Mgr: LastOwns 3the actions (for context).

  The Line BoardTarget (The Scoreboard)

  number

  Locatedbeing 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)displayed).

  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
  ErgonomicsLegibility	TouchDistance TargetsTest	ButtonsCritical ≥numbers 20mmreadable xfrom 20mm10 meters (30ft).
  VisualsSpeed	State Refresh	Machine state updates on screen in < 2 seconds.
  Logic	Color Coding	Green=Good,Red Red=Bad,= Blue=InfoStop/Fail. Green = Run/Pass. No aesthetic deviations.
  LatencyPace	Operator Screen	Response time < 500ms
  Content	LineHourly Board	Must show "Hour-by-Hour Target vs Actual vs. Target" (Delta)variance.
  ContentHygiene	HallwayStale Data	MustScreen showblacks out or shows "LineDisconnect" Status"icon +if "Topnetwork 3 Issues"fails.
  HardwareInput	DurabilityZero Touch	IP-ratedDisplays PCsrun on100% shop floorautonomously (Nono officemouse/keyboard desktops)
  Validation	Legibility	Text readable from working distance (2m for Terminals)required).