Digital toolkit for human-centered machine design: development and testing of an innovative system integrating virtual reality and HMI digital prototypes

Abstract Industry 5.0 (I5.0) emphasizes the importance of humans in modern manufacturing, particularly the need for efficient human-machine interaction. However, current design processes often neglect human factors in the early stages of machine design. Despite the growing recognition of human-centered design (HCD), existing methodologies still lack integrated solutions that fully leverage digital technologies for usability testing in industrial machines. As a result, traditional design and testing approaches remain rigid, limiting the potential of simulation in capturing complex human-machine interactions. This forces designers to rely on incomplete data, often leading to machines optimized for performance but lacking the usability needed for seamless human operation. This paper presents an innovative system that integrates humans into the design phase through two interconnected applications: a Virtual Reality (VR) application, where it is possible to interact with the machine digital model, and a desktop application that mimics the human-machine interface (HMI) to simulate operations on the machine. The two applications are synchronized and allow real-time interaction between the HMI and the virtual machine, enabling a human-centric virtual commissioning and testing of procedures that involve both the physical machine and the HMI. This approach enables iterative refinements before physical prototyping, reducing development costs while enhancing operational efficiency. By combining immersive engagement with the virtual machine and HMI simulation, it facilitates iterative refinements before physical prototyping, optimizing human-machine interaction and ensuring user-centered solutions. The industrial case study demonstrates the potential benefits of the proposed toolkit to optimize machine design according to I5.0 principles, improving both safety and usability.