Manufacturing leaders focused on curbing production delays are realizing they can’t afford to overlook one important factor: how well a Human Machine Interface (HMI) talks to its operators.
A modernized interface can mean the difference between a minor, 10-minute fix and a costly two-hour production delay. Without clear, real-time diagnostic data, even the most skilled operators are left guessing, and a simple electrical or mechanical hitch can become an extended production halt.
Clear communication is a primary driver of efficiency and a key to reducing manufacturing downtime, according to Von Eccles, Controls Manager at Automation Solutions (ASI).
“Some companies struggle to meet production goals because of their aging equipment or, in some cases, an underdeveloped system that isn’t working for their particular production needs,” Eccles said.
“An aging HMI with limited display capability can leave an operator in the dark, and a fix that could be made in minutes with the right information can lead to hours – or in some cases – days of downtime.”
Proactive companies are looking for custom HMI upgrades that move beyond the cookie-cutter approach to provide specific, actionable insights that keep lines moving, according to Eccles.
ASI Revitalizes Legacy PLC Platforms
While many facilities rely on aging infrastructure that still performs core tasks, these systems often lack modern capabilities. ASI works with manufacturing companies of all types to bridge the gap by revitalizing legacy PLC platforms, including systems like Allen Bradley, Seimens, Omron, Mitsubishi and others.
“By modernizing the interface of existing controllers, we are able to give manufacturing companies deeper diagnostics and more granular control,” Eccles said. “Providing more data to the operator allows them to make smarter decisions, reducing recovery time.”
This is especially critical for complex equipment such as vertical packaging machinery, where precise timing and synchronization may mean the difference between a perfect product and a wasted run.
The ASI Design Philosophy: Precision from Specification to Prototype
An effective HMI is a bridge between human intuition and machine logic. ASI’s solutions are built on a rigorous three-stage design process:
- Operator Interaction: Instead of basic cookie cutter designs, each application is unique. ASI works with operations to define a specification to offer the most intuitive interaction with the equipment, including critical alerts, alarms and navigation.
- Interface Software Specification: ASI translates needs into a technical framework that is robust and secure.
- Interface Software Prototyping: ASI develops and tests iterations to ensure the final product is highly intuitive for streamlined operations.
Secure, Reliable, and Built for Your Specific Needs
From food and beverage to heavy industrial applications, ASI’s custom HMI updates solve unique problems for a variety of industries. Whether the goal is to create next-level diagnostics, enhance or secure a manufacturing process with reduced downtime, ASI’s interfaces are engineered with industry knowledge, experience and a solid understanding of the specific needs of our clients.
Is your current interface providing the “big picture,” or are you operating in the dark?
Talk to an ASI integrator today to discuss how Automation Solutions can help turn your manufacturing downtime into a data-driven opportunity for improvement.
