The Imperative of Inclusive Design in Industrial Automation
In an era defined by rapid technological advancement and an increasingly diverse global workforce, the principles of inclusive design have transitioned from aspirational ideals to critical operational necessities. For the industrial automation sector, a domain characterized by complex machinery, rigorous environments, and a reliance on precision, embracing inclusivity is not merely a matter of corporate social responsibility; it is a strategic imperative for enhancing safety, boosting productivity, and securing a competitive edge. On March 4, 2024, Rockwell Automation, a global leader in industrial automation and digital transformation, unveiled detailed insights into its comprehensive, multi-faceted approach to embedding inclusive design across its hardware, software, and communication strategies. This report, building upon previous discussions, illuminates how the company is systematically addressing the unique challenges of making industrial environments accessible and user-friendly for all, acknowledging the intricate interplay between human factors, technological design, and linguistic clarity.
The industrial workforce is undergoing significant demographic shifts. An aging population, coupled with a growing emphasis on attracting diverse talent—including individuals with varying physical and cognitive abilities—necessitates a fundamental rethinking of how industrial tools and systems are designed. Statistics from the International Labour Organization indicate that approximately 15% of the world’s population lives with some form of disability, a demographic that is increasingly represented in professional settings. Furthermore, a 2018 Accenture study found that companies championing disability inclusion consistently outperform their peers across key financial metrics, including 28% higher revenue, 30% higher economic profit margins, and double the net income. These figures underscore the powerful business case for inclusive design, particularly in high-stakes environments like manufacturing and process automation where human-machine interaction is constant and critical. Rockwell Automation’s initiatives, as outlined, represent a forward-thinking response to these evolving workforce dynamics and market demands.
Redefining Hardware Design for a Diverse Workforce
The physical manifestations of industrial automation—robust machinery, control panels, and intricate sensor systems—are typically subjected to extreme conditions. These environments are often unpredictable, rugged, and can present significant challenges to human interaction. Unlike consumer electronics designed for controlled settings, industrial hardware must perform flawlessly "anywhere, anytime, and all the time," as previously emphasized by Rockwell. This inherent demand for resilience must now be paired with an equally robust commitment to supporting the needs of a diverse user base, including those with disabilities. To achieve this, Rockwell Automation is meticulously examining human factors in its hardware design process.
Engineering Ergonomics for Universal Access
Alex Mummert, a Senior Industrial Designer at Rockwell Automation, provided extensive insights into how the company is tackling the complexities of hardware design. He highlighted that industrial equipment placement typically falls into two categories: "on-machine" and "in-cabinet." The critical challenge lies in standardizing how information is displayed and accessed across these varied configurations, ensuring consistency without compromising utility. "Having unique options that could create an ideal solution in one scenario may wreak havoc in another scenario for the same type of product," Mummert explained.
To maximize accessibility, Rockwell’s design philosophy incorporates several key principles. Obstructions from the user interface are minimized, and display angles—both vertical and horizontal—are optimized to ensure legibility from various viewpoints. A paramount focus is placed on ergonomics, designing physical products to be as comfortable and intuitive to use as possible. Mummert detailed the company’s commitment to designing for the "99th percentile," meaning that grip points, pull force, and spatial affordances are standardized to accommodate the vast majority of the population without significant impediments. This robust approach is supported by rigorous testing, including low-fidelity ergonomic validations, such as the study depicted in Figure 1, which evaluated an I/O module’s door-opening feature in relation to nearby cabling. Such studies are crucial for confirming that design choices translate into practical, accessible solutions in real-world industrial settings.
Enhancing User Feedback through Smart Indicators and Responsive Interfaces
Beyond basic physical interaction, the legibility and responsiveness of industrial hardware interfaces are pivotal for inclusive design. Mummert underscored that industrial products rarely operate in pristine studio environments. Instead, they are confined to "cramped, poorly lit, and dirty environments with other pieces of cabling and equipment near or on top of them." Rockwell’s design strategy proactively addresses these variables, implementing modifications such as adjusting cabling direction and maximizing interface legibility. A clear hierarchy for both static and dynamic information—like a series of light indicators—is essential to minimize confusion and improve user experience under challenging conditions.
Indicators and lights, which communicate critical module statuses, receive particular attention. Mummert stressed the importance of ensuring that users progressively understand a module’s status through interaction, with the most vital information immediately noticeable. A significant development involves updated wavelength guidance for LEDs to enhance color identification for users with vision impairments. Previously, overlapping color specifications for green and yellow LEDs could lead to confusion; the new guidance aims to eliminate such ambiguities, particularly concerning blue-green and yellow-green indicators. Furthermore, Rockwell has increased the physical spacing between LEDs to maximize legibility in poor visibility conditions, accounting for both environmental factors and human vision impairments. This intentional spacing helps users discern individual indicators, preventing them from blending into a single, continuous color. Strategic LED placement also considers surrounding cables and other devices to ensure maximum visibility, a crucial factor in stressful situations where rapid identification of a product needing attention can prevent costly errors or even accidents.
User interface responsiveness is another critical element. Mummert emphasized the need for features that provide "distinct and consistent feedback," whether visual or physical, confirming that a task has been successfully completed. For example, a locking feature on a Programmable Logic Controller (PLC) must clearly communicate its locked or unlocked status with a definitive feel, even if it only requires a quarter turn. Crucially, designs must account for users wearing protective gear, such as gloves, which can reduce tactile sensation and add bulk. Testing solutions with similar gear in simulated environments is a standard practice to validate these scenarios. This holistic approach, encompassing over 400,000 individual stock-keeping units (SKUs), also considers brand perception and the entire product lifecycle—from unpacking and commissioning to maintenance and replacement—ensuring a cohesive and user-centric experience throughout. Further insights into Rockwell’s hardware specifications and accessibility initiatives are available via the ROK Talk podcast featuring Alex Mummert and Amber.
Modernizing Language: A Strategic Shift Towards Inclusive Terminology
Beyond the physical realm of hardware, language itself forms a crucial interface between users and technology. The technology industry, including industrial automation, has historically perpetuated outdated and non-inclusive terms that can alienate a significant portion of its user base and employee population. The challenge in the automation sector is particularly acute, given the decades-long lifespan of software and hardware solutions, and customers’ natural hesitation to alter anything that might disrupt established productivity. Recognizing this, Rockwell Automation has embarked on a strategic initiative to modernize its terminology, ensuring that all internal and external communications, whether hardware-oriented, software-oriented, or web-based, adhere to an inclusive language strategy.
Addressing Linguistic Legacy in Automation
The words used within user interfaces are fundamental to effective communication. As Rockwell’s user base and employee population become increasingly diverse, the clarity and inclusivity of terminology become paramount. Elena Dunne, Senior Manager of Industry Insights and a former terminologist, has been instrumental in spearheading this comprehensive effort to reform Rockwell’s linguistic landscape. She pointed out that "better terminology alternatives almost always exist," underscoring the feasibility of this transition. The move towards inclusive language is not merely about political correctness; it is about fostering clearer understanding, reducing cognitive load, and promoting a sense of belonging among all stakeholders. Studies have shown that inclusive language can significantly improve employee engagement and retention, and enhance brand reputation globally.
Rockwell’s Multi-pronged Approach to Terminology Evolution
Dunne detailed Rockwell’s multi-pronged approach to modernizing its terminology. The initiative began with external engagement, leveraging Dunne’s involvement with TerminOrgs, a consortium of terminologists from large organizations. This collaboration facilitated the discussion and identification of potential alternatives to non-inclusive terms. Rockwell then actively engaged with external parties, including standards organizations, partners, and customers who shared similar concerns and a desire for change. To broaden awareness, the company published a blog and created a dedicated page on its website (Figure 2), which continuously evolves to list preferred alternatives across various subdomains like cybersecurity, motion control, and software programming. Rockwell has also taken its message on the road, incorporating inclusive terminology discussions into the "Bold Conversations" roundtable talks at its annual Automation Fair® tradeshow for two consecutive years, most recently focusing on inclusive design and accessibility in Boston.
Internally, Rockwell has prioritized "proactive and transparent communication" from the outset. A Terminology Review Board was convened, employing various tactics to keep employees informed and engaged. These tactics include maintaining an internal website, distributing newsletters, utilizing Yammer for discussions, and providing comprehensive training programs. The effort is supported by a cross-functional working group leading five distinct workstreams, each focused on a specific aspect of terminology modernization. Critically, Rockwell is striving to embed these practices into its productization pipeline. With the newly formed Inclusive Design and Accessibility function, led by Amber, the focus is now on proactive measures—building checks into the development process to prevent inclusive-design and accessibility issues from developing in the first place. This integration ensures that inclusive language becomes an inherent part of product development, rather than a retroactive fix.
Integrating Accessibility into Digital Foundations: The Flourish Design System
While hardware and terminology address critical facets of inclusive design, the digital interface—the software that controls and monitors industrial operations—is equally vital. The industrial automation sector faces a particular challenge with legacy software solutions, many of which have been in operation for decades and were not originally designed with accessibility in mind. Retroactively updating these complex systems to meet modern accessibility standards is often a monumental, if not impossible, task. Therefore, Rockwell Automation has strategically shifted its focus to ensuring that all new software releases undergo rigorous implementation and testing of accessibility best practices and policies. A cornerstone of this strategy is the integration of accessibility into its internal Flourish Design System, as highlighted in Figure 3.
Proactive Accessibility in Software Development
Jonathon Gulbrandsen, Design System Leader at Rockwell, explained how the Flourish Design System is leveraged to drive the adoption of accessible, inclusive practices. Recognizing the breadth of considerations in building an accessible design system, the team wisely prioritized its efforts. "Our initial focus has been to ensure a proper contrast ratio [within] all our common componentry, [then] followed [up with] keyboard accessibility," Gulbrandsen stated.
The emphasis on keyboard accessibility proved particularly compelling to business leaders, as it offered a clear "win-win" scenario. Many software applications in industrial automation, such as Rockwell’s FactoryTalk® Design Studio, are immersive, integrated design environments (IDEs) used by "power users" like system designers and automation engineers. These users often prefer the speed and efficiency of keyboard navigation over mouse interaction, which can impose a physical and cognitive tax over an eight-hour workday. By designing for keyboard accessibility, Rockwell not only supports users with motor or visual impairments but also significantly enhances the productivity and comfort of its most frequent and demanding users. This dual benefit underscored the immediate value proposition, gaining ready support from leadership.
Prioritizing Key Accessibility Features and Compliance
To ensure appropriate contrast ratios, Rockwell adopted a compliance-driven approach, which also garnered leadership attention. The Design System team first ensured that all components met accessibility standards before they reached development teams. "For contrast ratio, we built into our component-design process a requirement to test and ensure that the ratio meets at least AA WCAG 2.1 standards for graphics and UI components, and we strive for AAA standards for text," Gulbrandsen affirmed. Compliance with modern web standards like WCAG (Web Content Accessibility Guidelines) is seen as a crucial way to build customer and user confidence, demonstrating Rockwell’s commitment to meeting the needs of an ever-diversifying global workforce. The WCAG standards are globally recognized benchmarks for web accessibility, providing a framework for making digital content more accessible to people with disabilities. Adhering to these guidelines not only fosters inclusivity but also often improves overall usability for everyone.
This work is an ongoing process. Gulbrandsen noted that "every component has an accessibility section within our documentation site that is ready for expansion as we continue to add capabilities that all of our products can use." Looking ahead, the team is working on making the design system "themeable," which will allow products to offer various visual presentations, such as dark or high-contrast themes. These themes are particularly beneficial for users with visual impairments or those working in environments with varying lighting conditions, further broadening the audience for Rockwell’s solutions.
Sustaining the Momentum for a Universally Accessible Industrial Future
Rockwell Automation’s comprehensive strategy for inclusive design—spanning hardware ergonomics, terminology modernization, and software accessibility—represents a significant commitment to fostering a more equitable and efficient industrial future. By establishing robust hardware design best practices, evolving its language to embrace a diverse global workforce, and embedding accessibility into the very foundation of its digital design system, Rockwell is laying down enduring foundations.
These efforts are not static but dynamic, reflecting an ongoing dedication to continuous improvement. As the industrial landscape continues to evolve, so too will the demands for inclusive solutions. Rockwell Automation’s proactive stance positions it as a leader in creating an industrial ecosystem that is not only technologically advanced but also universally accessible and user-centric. The momentum generated through these initiatives is strong, with future discussions planned to cover further critical areas such as Rockwell Automation’s external web presence, localization efforts, and other software standards in the upcoming Part 3 of this series. Ultimately, this holistic approach promises to enhance safety, elevate productivity, and ensure that the benefits of industrial automation are accessible to everyone, regardless of their individual abilities, thereby strengthening the entire industrial community.
