Pearson Packaging Systems, a leader in industrial packaging automation, envisioned a future where interacting with machines would be intuitive, efficient, and empowering for all users. They partnered with UpTop to help bring this vision to life through a Human-Machine Interface (HMI) that would serve as a catalyst for moving away from legacy systems and toward a more user-friendly, scalable platform.
Pearson Packaging Systems
Reimagining Human-Machine Interfaces at Pearson Packaging
Background
Challenges
Operators faced hurdles in navigating machine interactions—especially during complex tasks like changeovers and fault recovery. The legacy interface lacked clarity, real-time feedback, and adaptability for different experience levels or languages. Pearson needed to demonstrate a solution that answered a critical sales question: “If our HMI could do this, would you move off of Allen Bradley?”
Partnership Info
client
Pearson Packaging Systems
Industry
Industrial Automation / Manufacturing
type
Industrial HMI (Human-Machine Interface)
services
UX Research, UX Design, Prototyping, 3D Animation, Interaction Design, Design Specification
Partnership Info
client
Pearson Packaging Systems
Industry
Industrial Automation / Manufacturing
type
Industrial HMI (Human-Machine Interface)
services
UX Research, UX Design, Prototyping, 3D Animation, Interaction Design, Design Specification
Background
Pearson Packaging Systems, a leader in industrial packaging automation, envisioned a future where interacting with machines would be intuitive, efficient, and empowering for all users. They partnered with UpTop to help bring this vision to life through a Human-Machine Interface (HMI) that would serve as a catalyst for moving away from legacy systems and toward a more user-friendly, scalable platform.
Challenges
Operators faced hurdles in navigating machine interactions—especially during complex tasks like changeovers and fault recovery. The legacy interface lacked clarity, real-time feedback, and adaptability for different experience levels or languages. Pearson needed to demonstrate a solution that answered a critical sales question: “If our HMI could do this, would you move off of Allen Bradley?”
Approach
UpTop collaborated with Pearson and Automation Resources Group (ARG) through a phased engagement:
- Phase 1: Conducted workshops to explore user needs, technical constraints, and business objectives.
- Phase 2: Designed a hybrid storyboard-based demo with interactive workflows and 3D animations, refined through RITE (Rapid Iterative Testing and Evaluation).
- Phase 3: Delivered design specifications and visual guidelines to support future engineering rollouts.
Solution
The resulting HMI prototype introduced a forward-thinking user experience centered on real operator workflows. Key features included:
- Changeover Support: Step-by-step interactive guidance enhanced with 3D animations and a progress bar.
- Fault Recovery Tools: On-screen fault indicators, contextual instructions, and part lookup functionality.
- Maintenance Interface: Access to part numbers, machine health data, and quick navigation for diagnostics.
- Personalized Experiences: Login-based views tailored by user role and task history, with support for multi-language interfaces.
- Visual Dashboards: Real-time usage data and system health insights accessible from the HMI.
Further design refinements were made to improve contrast and usability in real-world plant environments, ensuring visibility and ease of interaction on the factory floor.
Results & Impact
Pearson emerged with a polished, innovative HMI demo that served both internal alignment and external sales goals. Outcomes included:
- Streamlined onboarding and task execution for operators
- Fewer errors during machine changeovers and fault resolution
- Increased buyer confidence in transitioning from legacy HMI systems
- A scalable design framework for future machine integrations
Through this collaboration, Pearson is positioned to lead in HMI innovation, transforming how operators work with machines and how customers perceive their technology.
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