The best controls engineer designs machines with the operator’s knowledge in mind, ensuring they are practical and easy to use. No IT system can replace an experienced operator who can sense when something isn’t right. Operators believe that if a machine is working, it’s best not to touch it, while controls engineers always want to understand why it’s working. A balance between these approaches leads to better efficiency, fewer breakdowns, and a smoother operation overall.

I have seen this a lot but one thing that is helping to close the gap is constant engagement of the operators and training on the basics of control. Another point is to make the operators feel important by upgrading them to technical operators which most organisations are doing now.

Operators are the backbone of any industrial system, yet too often, control engineers overlook their frontline expertise. The gap isn’t just technical—it’s a lack of mutual respect and communication. Engineers design for efficiency; operators deal with reality. Bridging this divide starts with active listening. When engineers involve operators in system design and troubleshooting, they gain invaluable insights that no manual can teach. Operators, in turn, feel valued and empowered. Technology connects systems, but collaboration connects people. The best-run facilities aren’t just automated—they’re aligned.

Engineers often try to create a flexible system with loads of opportunities for operators to control the system. It is difficult to keep the interface to the system simple but yet flexible enough for the operators. - engineers should focus on simplicity of the HMI - Graphics often help to clarify - requirements should be written down about what really matters for the operators so the focus will be in line with the expectation of the customer

I recommend reading The Prince by Niccolò Machiavelli. This political treatise explores power, leadership, and strategy, offering insights into how rulers maintain control. While written for politicians, its lessons on decision-making, adaptability, and pragmatism are highly relevant to engineers. In engineering, managing projects, navigating workplace dynamics, and making tough choices often require strategic thinking. Machiavelli’s ideas challenge conventional wisdom and encourage a results-driven mindset, making this a valuable read for engineers seeking to improve leadership, problem-solving, and negotiation skills in their careers.