3D Machine HMI
Connect live PLC states to a spatial machine overview so operators can read line condition, flow, and active zones at a glance
Our role
We defined the operator information hierarchy, prepared the 3D machine model, and connected PLC state semantics to a spatial UI through a maintainable signal and state mapping.
Competencies involved
The Problem
Many companies face similar challenges when trying to create value from their technical data and processes.
Conventional HMIs reduce complex machines to alarm lists and flat schematics. Operators know something failed but not where it matters physically, what changed recently, or which procedure applies. Under time pressure, experience replaces guidance, and every new hire starts from zero.
These challenges often result in concrete problems:
- Alarms appear as codes without spatial reference on the machine
- Troubleshooting on multi-station lines requires mental mapping from screen to floor
- Operators must navigate multiple screens to understand line flow, station readiness, and the overall effect of a local state
Why It Matters
Why does this matter? Look at the broader impact:
On complex equipment, the HMI is the daily manual. When it lacks context, stops last longer, procedures drift, and support absorbs preventable questions.
Key metrics we focus on:
Speed of locating faults on the physical machine
Consistency of operator procedures across shifts
Confidence of new operators when responding to deviations
Our Solution
Here's how we approach the solution:
3D machine overview bound to live PLC state and mode signals through a documented state-mapping layer
Spatial status layers that show station readiness, material flow, active zones, and abnormal conditions in the real machine layout
Overview-to-detail navigation that preserves context as operators move from the complete line to a station or component
Role-appropriate information hierarchy that prioritizes current condition and production flow without reproducing raw control tags
Results
The comparison between the starting point and the result shows the concrete value the solution can create.
Flat HMI screens that signal a problem without showing where or what to do next
PLC-connected spatial overview that makes machine state and line flow readable from one operator context
The concrete results include:
- Quicker orientation because live conditions are visible where they occur on the machine
- Stronger shared overview of station readiness and material flow across the line
- Less dependence on mental mapping between tag-based screens and physical equipment
Project context
A multi-station manufacturing line exposed detailed control data but gave operators no coherent spatial overview. neexo worked with automation and operations specialists to define meaningful state groups, map live PLC values to the 3D model, and design overview-to-detail navigation for daily line supervision.
Deliverables
- 3D HMI application with live PLC state mapping to machine geometry
- Spatial overview and station-level views for status, mode, readiness, and material flow
- Signal dictionary, state model, and mapping documentation for ongoing HMI maintenance
Related reading
Cases
Should your HMI show the machine, not just a list of tags?
We can help analyze your situation and identify opportunities for similar solutions.