How HMIs Drive Operational Efficiency and Resilience

    May 14, 2025
    Human machine interface (HMI) technology has evolved into a strategic asset that can address critical operational challenges such as the need for production efficiency gains and uninterrupted operations.
    OnLogic Tacton TC401 HMI
    Industrial touchscreens, like the OnLogic Tacton TC401, are specifically designed for use in challenging environments.

    Industrial environments have long been faced with challenges that impact productivity, safety and profitability. Beyond these issues common to many manufacturing operations, most notably extreme operating conditions, there are now issues associated with data overload, cybersecurity threats and the need for real-time insights — all of which demand careful consideration. 

    Fortunately, advances in HMI hardware and software technology can help mitigate these challenges by:

    • Minimizing downtime: HMIs equipped with robust environmental ratings and reliable components minimize the risk of hardware failures in harsh conditions. For example, in continuous processing plants, HMIs capable of withstanding extreme temperatures and vibrations promote uninterrupted monitoring and control. 
    • Data-driven decision-making: HMIs are instrumental in enabling data-driven decision-making in a single, unified hardware platform with integrated user interface and control. By integrating with data analytics platforms, these HMIs provide real-time insights into key performance indicators (KPIs), allowing operators to identify trends, optimize processes and improve overall efficiency. 
    • Edge computing and distributed control: HMIs are increasingly deployed in edge computing architectures, processing data locally and reducing reliance on centralized servers. This enables more responsive and resilient control systems, minimizing latency and improving real-time performance. 
    • Convergence of IT and OT: HMIs play a pivotal role in bridging the gap between IT and OT. By enabling data flow between different systems, HMIs facilitate a more holistic view of operations, enhancing collaboration and efficiency while allowing the right person to make and act on decisions. 
    • Strengthening cybersecurity: HMIs with secure boot, data encryption and robust network security protocols protect against unauthorized access and data breaches. 
    • Improving physical security: HMI systems can provide physical security features, such as limiting access to unused ports and cabinet intrusion-detection systems.

    In smart manufacturing facilities, HMIs serve as critical data hubs, integrating with MES and ERP software to provide a holistic view of operations. This enables real-time tracking of production, inventory and quality metrics, enabling managers to make informed decisions and optimize resource allocation.

    A variety of use case scenarios and their benefits

    To truly understand the strategic value of HMI technology across industry, let's examine some specific use case scenarios and explore the quantifiable benefits they deliver:

    • High-speed packaging: Here, an HMI with advanced processing capabilities can analyze real-time data from various sensors to optimize machine performance. By monitoring variables such as product flow and label placement, the HMI can identify potential bottlenecks and adjust machine parameters, leading to reduced changeover times and increased throughput. 
    • Remote oil and gas operations: In the extreme conditions commonly encountered here, HMI hardware plays a crucial role in ensuring operational efficiency. An HMI with robust environmental ratings and remote monitoring capabilities enables predictive maintenance, which reduces the need for on-site visits and lowers maintenance costs. 
    • Smart manufacturing facility: Here, HMIs serve as critical data hubs, integrating with MES and ERP software to provide a holistic view of operations. This enables real-time tracking of production, inventory and quality metrics, enabling managers to make informed decisions and optimize resource allocation. 

    What to look for in an HMI

    Choosing the right HMI for your needs can seem complex, but focusing on a few key considerations will help you make an informed decision.  First, look for an HMI that is durable enough to withstand the environmental challenges of its intended location. Key features include wide operating temperature and power input voltage range, ingress protection, high brightness readability, optical bonding, resistance to vibration and moisture, and flexibility in terms of screen size and touch type. 

    Make sure the HMI meets your specific input and output requirements and is compatible with your power source. 

    Finally, consider whether an all-in-one panel PC or a modular system best suits your needs. 

    See this in-depth guide to choosing HMI hardware for more information.

    David Zhu-Grant is the director of product management at OnLogic.

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