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Beyond the touchscre e can eliminate Factory F


Mark Walker,


operations director at Rencol, explains why tactile HMIs can help overcome operator error and ensure


industrial safety and productivity


M


otorsport is a proving ground for engineering innovations that inspire industrial design. At 300km/h,


Formula 1 drivers cannot glance down to confirm settings – every switch on the steering wheel must be identifiable by feel alone. Yet, factory operators routinely make critical adjustments on flat control panels offering zero sensory feedback. As visual software interfaces become the industrial norm, the essential modality of touch is often neglected. This gap is often where operator error


occurs. A study from TU Dresden and guidance from the UK Health and Safety Executive cite poor interface design as a factor that significantly increases operator error. When visual software replaces physical touch, hesitation and accidental inputs compromise safety and cause unexpected downtime. There is therefore a pressing need to treat


tactile HMI as an important pillar of industrial safety and productivity.


engineering feedback When visual confirmation is unsafe or impractical, tactile logic must take over execution. Consider an operator running a CNC machining centre: altering the feed-rate override requires attention to remain on the cutting tool to watch for flying debris. Forcing an operator to look away from the workpiece to locate a slider on a flat touchscreen introduces an immediate safety hazard. To build an error-resistant


physical interface, designers focus on three fundamental mechanical variables: • Rotary detents and calibrated torque: Unindexed dials can drift or be bumped unnoticed. Defined detents with specific torque allow operators to


1 DESIGN SOLUTIONS sePtemBer 2026 6


In Formula 1, every switch on the steering wheel must be identifiable by feel alone


count tactile ‘clicks’ to verify settings without breaking visual contact.


• Actuation force differentiation: Varying the force required for different controls helps operators recognise critical switches by touch. Higher resistance for major toggles prevents accidental triggers and unintended line stoppages.


• Physical recessing and guarding: High- consequence controls should not sit fully exposed on a panel. Recessing ensures that activation is a deliberate act rather than the result of an accidental bump.


material selection as a functional cue Unlike motorsport engineers restricted by weight, industrial designers can use material


On flat glass, an operator cannot feel a digital button or detect when a software slider reaches its limit


diversity to their advantage. Interfaces can exploit contrasts in texture and thermal conductivity to communicate function before an input is completed. For example, on a liquid packaging line


where moisture and condensation are constant, high-frequency tuning knobs used to sync conveyor speeds are best specified in high- friction thermoplastic elastomer, ensuring non-slip adjustments. Conversely, an adjacent master batch-override dial crafted from machined aluminium acts as an immediate sensory alert. The sudden shift in surface temperature signals to the operator that a high-consequence adjustment demands a slower, more deliberate action.


When standard components fall short While off-the-shelf components suit basic needs, recognising when standard hardware compromises safety is vital to reducing human error. Consider a pharmaceutical


cold-storage facility. Operators wearing thick insulated gloves frequently adjusted transport racks using standard spring- loaded detent plungers. The small, smooth knobs were difficult to grip with heavy gloves, causing frequent slips, missed locks, and hand fatigue. Replacing them with custom, oversized, T-handle plungers featuring exaggerated spring


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