STANLEY/STELLA 2025
DS OWNER
CARMEUSE 2021 - 2023
DS CONSULTANT
DEMATIC 2020
UI DESIGNER

Control room applications

Improved navigation and faster reactions to abnormal situations

UX LEAD

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Introduction

Carmeuse was redesigning its control room for limestone processing in Kosice (Slovakia), including both its physical and digital architecture. My team was responsible for designing the physical layout of the screens and the interfaces for production units and an overview screen.

Our goal was to create sober interfaces that can provide situation awareness at a glance, with faster reaction times to abnormal situations and more fluent navigation between units and subsystems.

Key responsibilities

Research

Our research plan included the following activities:

  • Workshops with Carmeuse stakeholders to gather requirements
  • Field observations and on-site interviews in three sites: We visited sites in Belgium and Slovakia to understand the operation, observe the way of working, and talk to operators and process engineers.
  • Expert review of current interfaces: We got to run simulations with the current applications and identify improvements from a usability point of view.
  • Study of standards for control room HMI design: Control room applications follow specific visual conventions, documented in ISA standards, with the latest being High Performance HMI (HP HMI). It is like a Design System existing only on paper.

We organised all the insights gathered with a reference to their source in an Airtable database, and organised them in the following themes:

  • Information architecture
  • Navigation
  • Context
  • Screen layout
  • Interactivity
  • Visual language.

We used the same themes to define design requirements, thus creating a clear link between design requirements and research findings.

Data visualisation of field study insights and their relations with design requirements

UX Design

In this project, UX covered navigation, physical and application screen layouts and design direction. I organised the work in design sprints, each sprint addressing some of the design requirements on these topics. Key moments of our sprints were design workshops during which we presented each other ideas and brainstormed on specific challenges.

The specificity of designing control room applications is that the entire room is the interface. Information organisation starts in the physical space. Drilling in the information hierarchy brings the user attention closer to a single screen.

Control room experience design entails:

  • Understand which systems require monitoring in different operational phases / scenarios and at which level of granularity.
  • Select a screen layout per operator that accommodates situation awareness and control needs.
  • Draw operator post ‘wireframes’.
  • Draw screen wireframes for different applications.

Interaction diagram showing the day shift work distribution among Dispatch (Loading Kosice and Slavec, Expedition Kosice and Slavec), Processing (Kosice and Slavec kiln and fuel tasks), and Administration (Training and Simulation with occasional operator presence).
Interaction diagram. Systems controlled and monitored by operators during day shift.

Diagram showing a Level 1 Overview display at the center with smaller labeled boxes representing systems like Kiln expert for 5 kilns, SF installation of KL5, KL6, KL7, K5 RK3, KL6 KL7, KL1 KL2, Bulk lime crushing and storage, Lime screening and crushing, Bricketing, Alarm summary, M.E.S (prism), and General purpose PC arranged around it.
Operator post wireframe

Hierarchical diagram showing four levels: Level 1 is Process Area Overview Display; Level 2 has three Process Unit Control Displays; Level 3 has three Process Unit Detail Displays; Level 4 has three Process Unit Support Displays.
Information architecture diagram.

Wireframe diagram of a global production unit showing sections labeled In, Connection Zone, Processing with shafts and channel, Out, and Navigation.
Screen wireframe

UI design

UI design was very much component-driven. We already started sketching some HP HMI components during the research phase, but during UI design, there was a dedicated designer working on the UI libraries while I and 2 colleagues worked on screen mock-ups. I was also responsible for the design backlog and QA for the entire team. Specifically for components, I often did a first draft sketch and documented component states and variations.

Components

Examples of components designed for process control equipment

Screens

Industrial dashboard showing energy and gas consumption, biomass, fuel, stone levels, kiln operation details, product handling and expedition data for Kosice and Slavce locations.
Industrial kiln control dashboard showing stone loading, blower room, kiln body with shafts data, air filter status, and lime quality graphs.
Control panel interface for solid fuel transport air, showing pressure, temperature, RPM, and amperage readings across multiple sensors and valves, with settings and production parameters on the left.
Industrial air filter control panel showing temperature, pressure, RPM, and safety switch statuses with navigation and action buttons on the left.
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