Optimised usability for complex HMI & SCADA systems

A facelift for your machine control system

Many machines and industrial systems are powered by highly advanced technology that is not immediately visible – because they are often operated through interfaces that have evolved over the years and now look visually outdated.

The clear goal is an interface that is more consistent and easier to use. What often discourages companies is the assumption that the entire control system needs to be reprogrammed – a highly costly and time-consuming process. In most cases, however, this is not necessary.

Instead, we optimise the user interface of existing HMI and SCADA systems based on your current system – from workflows, screens and navigation to individual on-screen components.

We can also implement our UX/UI concepts directly in Siemens WinCC or comparable HMI/SCADA systems using graphics, component or design editors. Your technical logic, control architecture and existing functions, however, remain the foundation.

Find out more below or book a free initial consultation to gain an overview of your system and the measures that can realistically be implemented within your existing environment:

When the machine can do more than its interface shows

In mechanical engineering, software is increasingly becoming part of the product experience. In reality, however, many machine manufacturers face the challenge that their existing control software works technically, but years of development by different programmers – often for perfectly valid technical reasons or in response to specific customer requirements – have made the interface visually inconsistent and difficult for machine operators to use.

This creates pressure to act: industrial customers expect a user interface that their employees can understand and use efficiently. Shorter training periods for changing operating personnel are also increasingly important, while strict requirements regarding ergonomics and safety must be met. User diversity is growing as companies expand into international markets, and sales teams need to communicate the software as an integral part of the machine more effectively.

A complete redevelopment of the control software is often neither planned nor economically viable. We therefore show how HMI challenges can be addressed through redesign and how an existing system can be sensibly optimised.

Optimal HMI redesign for Bekum Control 8.0
Optimal HMI redesign for Bekum Control 8.0
How HMI and SCADA systems work – and where we come in

An industrial HMI or SCADA system connects operators with a machine or industrial system. The HMI is the visible layer of this system: screens, faceplates, controls, status displays, charts, buttons, navigation and role logic.

An HMI redesign does not mean rebuilding the entire machine control system. Instead, we work on the presentation and interaction layer to address typical problems found in interfaces that have evolved over time. The redesign is based on the possibilities and limitations of your existing HMI or SCADA framework. The result is a practical interface that can also be implemented technically.

Typical consequences of screens that have evolved over time:

  • Overloaded process screens with unclear states and missing hierarchies
  • Inconsistent UI elements such as colour palettes and icons
  • Different interaction patterns across screens, long click paths for frequent tasks and unclear navigation
  • Poor readability on older panels or under difficult lighting conditions
  • Interfaces that rely heavily on the experience and knowledge of individual operators

Screen elements and approaches to optimisation:

  • Screen structure, information architecture, navigation and operating workflows
  • Alarm and warning logic at UI level and consistency across machine modules
  • Faceplates, components and states
  • Colours, icons, typography and contrast
  • Role- and use-specific views
  • Touch usability and panel ergonomics
01
UX/UI review

We analyse your existing HMI or SCADA interface from a usability perspective. The result is a concrete assessment: Which areas already work well? Where do unnecessary usability barriers occur? Which screens are overloaded? Which components should be standardised? And which optimisations can realistically be implemented within your existing system?

02
HMI redesign

Based on the analysis, we develop a new UI concept for your existing interface. We consider the requirements of operators, service teams, commissioning teams, sales and your internal engineering teams. A good HMI must be understandable, quick to interpret and reliable to operate in day-to-day use.

03
Technical implementation in the HMI/SCADA system

In addition to developing the UX/UI concept, we can also implement it in the respective HMI or SCADA environment. Our focus is on Siemens WinCC and WinCC-based systems. Depending on the project, we are also happy to assess other SCADA or HMI frameworks.

As part of the project, we create reusable UI components within existing templates and libraries:

  • Screens, layouts & navigation
  • Faceplates and components
  • Colour palettes, icons and status indicators
  • Alarm and status management

The goal is a clean implementation that remains transparent and understandable for your internal teams and integrates into the existing engineering environment.

Same system.
Better interface.

An HMI redesign modernises the visible layer of your machine control system without rebuilding the existing technical foundation. The existing technology remains the basis. The user interface becomes clearer, more consistent and easier to use – reflecting the quality of the machine itself. Let us assess, without obligation, what is possible within your existing system:

Guided by standards and industrial practice

An HMI in mechanical engineering must work under real-world conditions: shift operation, changing lighting conditions, touch panels, gloves, time pressure and international operator groups with different levels of experience.

That is why our analysis and redesign process considers relevant principles from ergonomics, human-system interaction, information presentation and industrial HMI design. Depending on the application and industry, standards such as ISO 9241, ISO 11064, ISA-101 and SEMI E95 may also be relevant.

Good HMI design does not replace a safety assessment of the machine. However, it makes a significant contribution to how safely and efficiently operators interact with the machine.

Why PESCHKE?

PESCHKE has been working with industrial companies and machine manufacturers for more than 50 years. We combine this experience with expertise in UX/UI, software development, industrial design and engineering.

For HMI projects, this means that our team considers design and system limitations together. This allows the HMI to work within the existing framework, integrate into established engineering processes and make operators’ daily work easier.

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Our HMI design clients choose us for a reason.

We believe in our clients' vision and know: Only their success makes us successful too.

That is why we are fully committed to being a flexible and reliable partner – backed by decades of experience, specialist expertise and up-to-date market knowledge.

Technology, design, implementation: questions about HMI redesign

When does an HMI redesign make sense?

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An HMI redesign makes sense if you recognise one or more of the following challenges:

  • The machine is technologically advanced, but the user interface looks outdated.
  • The system currently requires too much training and experience to operate safely.
  • The existing control system should continue to be used and a complete reimplementation is currently not planned.
  • Your customers are increasingly evaluating the machine’s user interface as well.
  • Sales and marketing teams find it difficult to present the software as a product advantage.
  • Different machines or modules should have a more consistent operating concept.
  • Internal teams need a solution that remains maintainable and transparent.

Can the designs also be implemented in other SCADA or PCS software?

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We specialise in Siemens SIMATIC WinCC v7/v8, but can generally also work with other SCADA, HMI or PCS systems, provided they offer suitable options for UI customisation – for example through a design editor, graphics editor or CSS editor. These include systems such as Siemens SIMATIC WinCC OA (Open Architecture), Ignition, AVEVA System Platform, Rockwell FactoryTalk and GE Vernova Proficy CIMPLICITY or iFIX. During a free initial consultation, we analyse your tech stack and discuss which adaptations can realistically be implemented. For further project steps, a suitable software licence or test environment may need to be provided.

In what form is the new HMI design delivered?

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The exact deliverables depend on the HMI or SCADA system being used. Depending on the software, the redesign can be delivered as a UI concept, design system, screen design, component library, style guide or as a directly implemented adaptation within the existing framework. During a free initial consultation, we analyse your tech stack and jointly define the appropriate project process – from the design phase through to potential integration into your system.

What distinguishes PESCHKE from a traditional HMI design agency?

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We do not design HMI interfaces in isolation from technical reality. Instead, we consider the existing software environment, its possibilities and its limitations from the very beginning.

Elaborately designed interfaces can often only be implemented to a limited extent in existing HMI systems or require considerable implementation effort. With our experience in industrial applications, HMI frameworks and industry-specific requirements, we develop designs that not only look good but can also be realistically implemented within the respective system.

How does PESCHKE differ from a traditional process automation or SCADA agency?

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Our focus is on the interface, usability and operator experience. We look at the HMI from the perspective of the people who work with the system every day: Which information is important? Which states need to be recognised quickly? Which workflows can be made clearer, safer and more efficient? We focus on UX/UI design, visual structure, operating logic and interaction quality – without putting the process itself or the system’s fundamental functionality at the centre of our work.

Can I update my HMI during ongoing operation?

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Whether an HMI redesign can be implemented during ongoing operation depends on the respective system, the system architecture and your internal approval processes. Our approach is designed to work as closely as possible within the existing HMI environment and to make targeted adaptations at UI level. Depending on the project, the redesign can be planned as a step-by-step optimisation of individual screens, a more comprehensive interface modernisation or as part of a larger process or system change.

My HMI needs to comply with certain standards or industry requirements – can PESCHKE support me?

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We consider relevant standards, guidelines and industry-specific requirements within the design process and can incorporate them into the analysis, concept development and design of your HMI. The relevant standards depend heavily on your industry, application and target environment. In your enquiry, please describe the industrial sector in which the HMI is used and which standards or internal requirements are important for your project. Based on this information, we can assess the requirements more specifically during the initial consultation.

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