Despite the rapid adoption of digital tools in manufacturing over the past decade, the Human-Machine Interface (HMI) has remained strikingly similar to the digital HMIs that emerged in the mid-1990s. Traditional, "locked" HMIs create information bottlenecks that hinder efficiency and limit data accessibility. Additionally, HMIs are often fixed systems with infrequent updates and no configurability. The limitations of existing HMI design lead to redundant operator input, siloed data, and the frustration of navigating multiple screens in order to get the job done – ultimately slowing down production and obscuring valuable insights. We need a new approach, one that puts humans at the forefront and fosters seamless interoperability.
Existing HMI systems face two main challenges. First, they have no access to operational data. This valuable on-machine real estate is reserved for controls. Operators must bring along paper work orders, USB sticks, and other external data in order to perform their jobs.. Second, traditional HMIs often give insufficient consideration to the operator's experience. Complex parameter configuration, difficult troubleshooting procedures, extended training periods, and inadequate shift-to-shift communication collectively contribute to diminished productivity and an increased likelihood of errors.
Composable HMIs: A New Paradigm
Composable HMIs represent a significant leap forward, fostering unprecedented interoperability between machine and human processes. This future-thinking approach to HMI embeds composable apps into a traditional HMI, with bi-directional communication between control systems and apps. This modern approach allows manufacturers to tailor HMIs to specific workflows, roles, and processes, resulting in a more intuitive and efficient user experience. cHMI presents a unified user operator interface that integrates MES, CMMS, work instructions and maintenance procedures, with controls, real-time PLC communication, and machine programs.
Why Embrace Composable HMIs?
Improved workflows: Less time switching between systems means more time focused on the task at hand.
Error Prevention: By enabling parameters to be set directly from platforms like Tulip, composable HMIs minimize the risk of transcription errors, dramatically improving data accuracy and reliability.
Deeper Insights: Composable systems break down these data silos and provide a unified view of human and machine data. This comprehensive perspective empowers manufacturers to gain deeper insights into their operations, more easily identify trends, and make truly data-driven decisions.
Shorter Training Times: Standardized user interfaces (UIs) across machines simplify operator training, reducing the learning curve and accelerating proficiency.
Accelerated Troubleshooting: Composable HMIs can integrate advanced technologies such as AI-powered chatbots trained on machine manuals, enabling much faster and more effective troubleshooting.
Real-World Applications and Partnerships
Tulip is already working with leading partners to demonstrate how Composable HMIs are being implemented across various industries:
DMG MORI: Tulip's pre-built apps on DMG MORI CELOS-X accelerate operational digitalization, providing operators with intuitive, machine-specific guidance.
Rockwell Automation: Tulip apps on Rockwell Automation Optix augment machine setup, eliminate data silos, and capture contextualized data through a unified, human-centric interface.
Inductive Automation (Ignition): Tulip enhances SCADA/DCS systems with intuitive HMIs for legacy machines, streamlining setup, work order management, and downtime data capture.
Mitsubishi Electric (ICONICS): Tulip apps on Mitsubishi HMIs, via ICONICS integration, replace siloed data sources with operationally contextualized machine data. This integration also enables automated actions, such as prompting operators for downtime reasons when a machine E-Stop is triggered.
Sartorius: Sartorius is partnering with Tulip to enhance its Biobrain automation platform with composable HMIs, aiming to revolutionize biopharmaceutical production. This collaboration will provide Sartorius customers with robust digital solutions for commissioning, operating, and maintaining their equipment, supporting digital transformation and ensuring regulatory compliance.
Honeywell: Tulip combined with Trackwise Digital (MES, QMS), integrates QMS, MES, and Frontline Apps for a complete eDHR and Quality Solution.
Composable HMIs are transforming the manufacturing landscape by prioritizing human-machine collaboration and breaking down traditional data barriers. By partnering with leading automation and technology providers, companies like Tulip are empowering manufacturers to achieve new levels of efficiency, productivity, and insight.
The future of HMI is here, and it's composable.