ISB Merlin 4000

Context

Redesigning the Merlin press brake system with a touch interface, automation, and real-time feedback will boost efficiency, reduce errors, and enhance safety.

Role

UXUI Designer

Timeline

3 Months

Core Features

Core Features

Automated Learning

7” multilingual display with intuitive controls for faster onboarding and training.

Automated Learning

Dynamic adjustment of safety parameters reduces manual input and user errors.

Seamless Data Management

USB backup and near-unlimited job storage improve user control and efficiency.

Automated Learning

7” multilingual display with intuitive controls for faster onboarding and training.

Automated Learning

Dynamic adjustment of safety parameters reduces manual input and user errors.

Seamless Data Management

USB backup and near-unlimited job storage improve user control and efficiency.

Development Process

Research

While I conducted primary and secondary research, engineering assessed the device’s limitations. Since this was a full overhaul of the Merlin 3000, understanding our capabilities was crucial.

Synthesis

After identifying client concerns through research, I presented my findings to stakeholders, highlighting the most critical updates for the Merlin 4000.

Conceplization

I created mockups and user flows while engineering finalized the device resolution and other specifications.

Development

Once both the design and engineering teams approved the designs, we developed a prototype for real-world testing in a controlled environment. The testing process was intensive and required travel to various sites.

Identifying problems with the Merlin 3000

The Merlin 3000 press brake guarding system has issues with error messages like 'Hazard' and 'No Column,' causing safety concerns. Older press brakes also require custom modifications for proper integration and compliance.

Findings from Primary Research

I conducted quick interview via phone calls to the sites directly and speak with facility managers. I wanted to first get a quick grasp on how they operate on a day to day basis. While doing this, the engineering team visited a few sites to see how they set up their systems directly. We took on the sites that were highly interested in updating their systems.

Main Feedback

Outdated Interfaces

Basic displays with limited interactivity, making navigation less intuitive.

Complex Interface Navigation

Older models used non-touch, button-based HMIs, making navigation cumbersome and increasing user errors. This led to longer learning curves, extended onboarding, and trust issues with the system.

Manual Adjustments

Users needed to manually configure safety settings, increasing cognitive load.

Limited Data Access

No easy backup or job storage, leading to inefficient workflows.

Outdated Interfaces

Basic displays with limited interactivity, making navigation less intuitive.

Complex Interface Navigation

Older models used non-touch, button-based HMIs, making navigation cumbersome and increasing user errors. This led to longer learning curves, extended onboarding, and trust issues with the system.

Manual Adjustments:

Users needed to manually configure safety settings, increasing cognitive load.

Limited Data Access

No easy backup or job storage, leading to inefficient workflows.

Findings from Primary Research

I conducted quick interview via phone calls to the sites directly and speak with facility managers. I wanted to first get a quick grasp on how they operate on a day to day basis. While doing this, the engineering team visited a few sites to see how they set up their systems directly. We took on the sites that were highly interested in updating their systems.

Main Feedback

Outdated Interfaces

Basic displays with limited interactivity, making navigation less intuitive.

Complex Interface Navigation

Older models used non-touch, button-based HMIs, making navigation cumbersome and increasing user errors. This led to longer learning curves, extended onboarding, and trust issues with the system.

Manual Adjustments:

Users needed to manually configure safety settings, increasing cognitive load.

Limited Data Access

No easy backup or job storage, leading to inefficient workflows.

Statistics and Secondary Research

We started with in-depth secondary research using the data from our Pendo and drawing hypotheses and insights on what needs to be worked on exactly.

30%

User Satisfaction

57%

Profile Errors

24min

Average Time Spent

Ideation - Development of Ideas

In Phase 1 of ideation, engineering debated between a fully touchscreen interface or a hybrid with buttons and a key lock switch. Ultimately, the Merlin 4000 v2 moved forward with a full commitment to a 7-inch touchscreen, eliminating all physical buttons.

Low-Fi Mockup

After extensive discussions with the team to identify key themes and align stakeholders on the direction, we began with low-fidelity mockups to establish a clear vision for the design approach.

Hi-Fi mockup

After finalizing low-fidelity designs with the product manager, I introduced larger configuration profile buttons with icons for easy identification. Simplicity and accessibility were key, especially for emergencies, while maintaining design continuity remained a top priority.

Safety Status Alert UI

Enter here

Validating the designs

why did we make these design decisions

UI Choice

Large and accessible UI to showcase what mode the Merlin is and if it safe for operation

UI Choice

Large and accessible UI to showcase what mode the Merlin is and if it safe for operation

Program P indicator on MX columns

The MX columns will have a small screen to indicate what mode it is in. A simple P is enough for a worker to see what mode the MX column is in and that it is no operationtional untill the P and the Red LED is switched off

Image of heatmap
Image of first click test

“Alerts are clearer, and I’m less likely to miss critical warnings during high-pressure situations.”

-Annonymous User

"I like the fact that both the MX columns and the Merlin work well together. Sometimes, I'm not near the Merlin, but I can see the situation on the MX columns as well. That's a huge bonus for me.”

-Annonymous User

Validating the designs

why did we make these design decisions

UI Choice

Large and accessible UI to showcase what mode the Merlin is and if it safe for operation

Program P indicator on MX columns

The MX columns will have a small screen to indicate what mode it is in. A simple P is enough for a worker to see what mode the MX column is in and that it is no operationtional untill the P and the Red LED is switched off

Image of heatmap
Image of heatmap
Image of first click test
Image of first click test

“Alerts are clearer, and I’m less likely to miss critical warnings during high-pressure situations.”

-Annonymous User

"I like the fact that both the MX columns and the Merlin work well together. Sometimes, I'm not near the Merlin, but I can see the situation on the MX columns as well. That's a huge bonus for me.”

-Annonymous User

Final Results

Post-launch, I gathered data through client surveys, usage analytics, and error logs. Metrics showed increased upgrades to the Merlin 4000, fewer programming errors, and reduced training time due to improved navigation.

76%

Clients would Switch to Merlin 4000

89%

Fewer Programming Errors

22min

Drop in Training Time

Brainstorming on whiteboard
Convincing stakeholders
Discussing and ideating

Reflections

Unique UXUI Experience

This project was unique as it blended HMI design with digital UX/UI, ensuring seamless interaction between physical controls and a modern touch interface. It prioritized efficiency, safety, and usability while meeting industrial and ergonomic standards.

Collaboration

Collaboration with engineering was crucial to ensure the design aligned with hardware capabilities, safety standards, and real-world constraints. Their input helped refine feasibility, optimize performance, and integrate UX/UI seamlessly with the physical system.

Think Outside the Box

Thinking outside the box was essential to reimagining the user experience beyond traditional HMI design. By challenging standard interfaces, we introduced a more intuitive touch-based system, streamlined workflows, and reduced errors. This approach allowed us to push past limitations and create a more efficient, user-friendly solution.

Identifying problems with the Merlin 3000

The Merlin 3000 press brake guarding system has issues with error messages like 'Hazard' and 'No Column,' causing safety concerns. Older press brakes also require custom modifications for proper integration and compliance.

Identifying problems with the Merlin 3000

The Merlin 3000 press brake guarding system has issues with error messages like 'Hazard' and 'No Column,' causing safety concerns. Older press brakes also require custom modifications for proper integration and compliance.

Ideation - Development of Ideas

In Phase 1 of ideation, engineering debated between a fully touchscreen interface or a hybrid with buttons and a key lock switch. Ultimately, the Merlin 4000 v2 moved forward with a full commitment to a 7-inch touchscreen, eliminating all physical buttons.

Low-Fi Mockup

After extensive discussions with the team to identify key themes and align stakeholders on the direction, we began with low-fidelity mockups to establish a clear vision for the design approach.

Hi-Fi mockup

After finalizing low-fidelity designs with the product manager, I introduced larger configuration profile buttons with icons for easy identification. Simplicity and accessibility were key, especially for emergencies, while maintaining design continuity remained a top priority.

Safety Status Alert UI

Enter here

Ideation - Development of Ideas

In Phase 1 of ideation, engineering debated between a fully touchscreen interface or a hybrid with buttons and a key lock switch. Ultimately, the Merlin 4000 v2 moved forward with a full commitment to a 7-inch touchscreen, eliminating all physical buttons.

Low-Fi Mockup

After extensive discussions with the team to identify key themes and align stakeholders on the direction, we began with low-fidelity mockups to establish a clear vision for the design approach.

Hi-Fi mockup

After finalizing low-fidelity designs with the product manager, I introduced larger configuration profile buttons with icons for easy identification. Simplicity and accessibility were key, especially for emergencies, while maintaining design continuity remained a top priority.

Safety Status Alert UI

Enter here

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