Smarter Interfaces, Smarter Robots: How ExD Built an AI-Powered Human-Machine Interface (HMI) for MAIROTEC

MAIROTEC set out to modernize how operators interact with industrial robots. The goal: a faster, smarter, and more intuitive Human-Machine Interface (HMI) that could match the functionality of leading systems like KUKA SmartPAD—but tailored for their specific needs.

To bring this vision to life, MAIROTEC partnered with Excellence Delivered (ExD) to design and develop a web-based, low-latency HMI that enhances control, programming, and real-time monitoring, redefining how operators manage robotic systems on the ground.

The Challenge

MAIROTEC’s existing setup couldn’t keep up with the growing complexity of its robotics workflows. The key pain points were:

• Slow response times between the interface and the robot
  A noticeable delay between a user’s command through the interface and the robot’s response made operations difficult to scale. This is especially critical for industrial robots performing tasks on heavy machinery, such as vehicles, where response latency could lead to severe consequences.
• Manual, fragmented programming with little real-time feedback
  Programming the robots had to be done manually, disjointedly, without any live feedback, making it time-consuming and harder to correct mistakes on the spot.
• Disconnected modules for grippers and teach points
  The tools used to control robot grippers and set up “teach points” (predefined movements or positions) were not integrated into one system, which complicated the workflow.
• No centralized user management or role-based access
  No system was in place to manage different users or assign permissions based on roles, which could lead to confusion or security concerns.

Lack of future scalability for SDK deployment or licensing
The system was not built in a way that could easily support future upgrades, such as SDK (Software Development Kit) integration or licensing models—limiting its long-term potential.

MAIROTEC required a unified, scalable, intuitive solution for operators — powerful enough to scale with the business.

ExD-Powered AI: Building a High-Performance HMI

The team at ExD carried out extensive research to design and implement a robust, AI-enhanced Human Machine Interface (HMI) platform from the ground up, balancing simplicity for end users with advanced technical capabilities at the core.

Key Features Delivered:

1. Redesigned UI for smooth navigation, faster control, and better visual clarity.
2. Real-time communication with robots to ensure low-latency performance.
3. Integrated robot control, including ‘Move Home’ and ‘Actual Home Position.
4. Teach point-based programming with database-backed storage and retrieval.
5. Gripper module integration, tested and deployed via the Snap app.
6. Path planning tools connected to teach points using custom APIs.
7. Real-time error display for faster issue resolution.
8. Tool & base selection built into the interface for contextual accuracy.
9. User management with secure logins, role-based access, and full integration into the Snap app.

Log file functionality to track actions and improve troubleshooting.

All components were fully integrated into a responsive web interface built for real-world use on factory floors.

The Impact

The new HMI system, powered by ExD, delivered immediate improvements across the board:

• Command latency was cut significantly, speeding up every task.
• Programming became faster and more precise thanks to teach point tracking.
• Gripper control and path planning were now fully visual and connected.
• Real-time visualization enabled faster responses and fewer errors.
• Operators had full control, with role-based access and a more intuitive interface.
• The system is now SDK-ready, with future deployment and licensing seamlessly integrated.
  

MAIROTEC now operates with a centralized, high-performance platform that simplifies robot management and scales with its needs.

Conclusion

What started as an interface upgrade became a full-scale digital transformation. ExD’s AI-driven HMI solution has equipped MAIROTEC with the tools to manage robots faster, smarter, and more efficiently than ever.

With deep expertise in full-stack development, industrial automation, and intelligent interfaces, ExD continues to help manufacturers like MAIROTEC unlock the next level of performance in their operations. 

As SAP Platinum Partner with a strong portfolio of AI and automation solutions, Excellence Delivered (ExD) empowers organizations to embrace innovation across every layer of their operations. Our work with MAIROTEC reflects our ability to merge industrial needs with cutting-edge technology, building scalable, intelligent systems that enhance performance and future-readiness. Whether it’s transforming interfaces or redefining control systems, ExD remains at the forefront of digital engineering and smart manufacturing solutions.