HMI design: ergonomics and trends from manual to fully automated

Product and Industrial Design User Experience Design (UX) User Interface Design (UI)

HMI design trends and ergonomics: from manual control to full automation

In Part 1 of this blog article, we discussed the definition of HMIs, the role of tactile control elements, Operator Experience and the fundamental benefits of well-designed interfaces.
In Part 2, we explore the different levels of automation in HMI systems, how process reliability and ergonomics can be ensured, and which developments – from system interfaces to digital twins – are shaping the future of machine operation. The goal remains the same: safe, efficient and error-free interaction between humans and machines.

March 17, 2026

Solutions from manual to fully automated

Machine operation covers a wide spectrum of solution approaches, ranging from purely manual systems to fully software-controlled automation. As systems move towards increasingly “smart” capabilities, the HMI shifts from physical controls to connected and often mobile interfaces. Each stage in this spectrum requires its own carefully considered HMI design concept:

Hybrid solutions can also be the ideal choice – for example, a stationary touch panel for detailed intervention combined with a mobile dashboard for fault monitoring. The key is to analyse the operating context for each functional level (“hands-on” versus “hands-free”) and design modular interfaces accordingly.

HMI design helps address real operational challenges

As discussed in Part 1 of this article, professionally designed HMIs provide numerous advantages across areas such as efficiency, ergonomics, safety and economic performance.

These benefits become particularly visible when considering the everyday challenges faced by machine operators. HMI design is built around these real-world requirements and provides solutions that simplify daily work.

Whether through intuitive workflows that minimise training time or logging functions that support service diagnostics, modern HMIs often solve problems before they are even perceived as such.

Operational challenges and HMI solutions

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Drawing on our experience of working with global market leaders, we bring in-depth expertise and a deep understanding of industrial requirements. Our focus is on developing intuitive and future-proof HMIs that highlight the strengths of your product. Together, we create solutions that not only work but also deliver an outstanding user experience.

Are you planning a new project? Feel free to contact us for a non-binding (and, of course, free) initial consultation. We look forward to hearing more!

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Design process according to DIN EN ISO 9241-210

HMIs are not designed based on personal preferences. They must comply with established standards and regulations. One of the most important frameworks is ISO 9241-210. Following this standard, the design process includes several iterative cycles. Each prototype is tested, evaluated and refined based on insights gained during usability testing until the most suitable design is ready for rollout.

Sustainability and ergonomics as competitive advantages

Sustainability and ergonomics are becoming increasingly important in HMI design – both for machine operators and manufacturers.

1 – Durable and repairable systems

Modular housing concepts and standardised components simplify maintenance and replacement. This extends machine lifespan and reduces service costs over the entire product lifecycle (Modular Management).

2 – Ergonomics in demanding environments

In production environments, HMIs must remain operable while wearing gloves, during vibration or in conditions with limited visibility. Clear button layouts, tactile feedback and well-positioned controls improve both safety and efficiency in daily operation (LTS Group, 2023).

3 – Energy and resource efficiency

Intelligent power management for displays and computing units can reduce energy consumption and thermal load, benefiting both sustainability and overall system stability.

A well-designed HMI therefore combines environmental considerations, operational reliability and user comfort into a clear competitive advantage.

Beispiele nachhaltiger und ergonomischer Bedienelemente

Trends in HMI product design

Modern human-machine interfaces are evolving from simple control panels into context-aware assistance systems. The focus lies on intuitive operation, reduced cognitive load and stronger integration into industrial environments. At the same time, digitalisation, AI and growing safety requirements are accelerating development. Key trends in HMI product design include:

1) Intelligent and adaptive interfaces

Increasingly, HMIs use data analysis and artificial intelligence to support operators proactively (McKinsey Technology Trends Outlook, 2025). Systems can prioritise relevant information or detect maintenance requirements early. Role-based interfaces that adapt to different user groups are also gaining importance (MIT Technology Review, 2025).

2) Multimodal and assistive interaction

Touch interfaces are increasingly complemented by additional input methods such as voice control, gesture interaction and mobile devices. Technologies such as augmented reality and digital twins support operators during complex tasks, maintenance activities and training (MIT Technology Review, 2025).

3) Software-defined HMIs & connected interfaces

Machine functions are increasingly implemented in modular software layers. This enables HMIs to evolve more quickly, simplifies maintenance and allows reuse across different machine platforms. They exchange data with MES, ERP or cloud systems via open interfaces, thereby enabling better analysis and more efficient maintenance processes.

4) Reduced, information-focused UI design

Industrial HMIs prioritise clear visualisation and structured information hierarchies. Minimalist interfaces with high readability reduce operating errors and accelerate decision-making (Interaction principles as per DIN EN ISO 9241-110).

5) Hardware integration and sustainability

New display technologies, energy-efficient hardware and durable materials are becoming more important. Many systems continue to combine touch displays with physical control elements, especially in safety-critical environments (Fraunhofer IAO).

6) ‘Security by design’

With growing connectivity in industrial systems, cybersecurity becomes a core component of HMI design. Authentication, access control and secure communication protocols must be considered already in the concept phase (IEC 62443 Industrial Security Standard).

Future HMIs will become more context-sensitive, data-driven and tailored to different user groups. The ultimate goal remains the same: enabling safe, efficient and reliable interaction between humans and machines.

Maschinensteuerung CC300 plus in der Nahaufnahme

ENGEL AUSTRIA GmbH

HMI – control unit CC300 plus

Ergonomic and customisable control unit with touchscreen – for the efficient execution of complex operating procedures.

BEKUM Maschinenfabriken GmbH

HMI design relaunch

Touchscreen machine control system offering maximum operational reliability and a clear display of process parameters for different user roles.

PESCHKE – your partner for strong HMI solutions

Through our collaboration with global market leaders across various industries, we bring extensive expertise and a deep understanding of industrial requirements to every project. Our focus is on developing intuitive and future-proof HMIs that combine outstanding industrial design with carefully crafted UX/UI concepts. The result: solutions that optimise your processes while delivering an exceptional user experience.

On our pages covering UX design, UI design and product & industrial design, you can learn more about how we work.

Are you planning a new project? feel free to contact us for a non-binding initial consultation. We’d love to answer your questions and discuss the options best suited to your specific project. We look forward to learning more about your challenges and ideas!

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