HMI IN PHARMACEUTICAL INDUSTRY

HMI: -it is a component of a device that allows interaction between human

operators and machine.by using this machine operator can control and
operate the process by interacting with the supervisory system.an also
collects all the data from the external devices and create reports and
performs alarming and send notifications etc. and it is employed with zenon
or glatt software for automation.

Following are the key features of hmi:-

 Hmi work in both auto and manual mode.if there is any error during a
process.it can be turned to the manual mode to ensure the continuity of
the operations.

 Hmi consists of display unit with function buttons to control or operate a

process which makes the user able to monitor or control the undergoing
batch process.

 Hmi is generally a touch screen to the plc.

SCADA:-scada (Supervisory Control And Data Acquisition) is a system

operating with coded signals over communication channels so as to provide
control of remote equipment.SCADA collects the information,transfer it
back to the central site , and then display that information on a operator
screen or displays.

Scada consists of following components:-

 Supervisory system: -It is the heart of the scada(supervisory control

and data acquisition) system .which gathers information or data from the
ongoing process and send the commands to the field connected devices.

 Remote terminal units(RTU’s):-these are connected to the sensors, and

actuators in the process,and are networked to the supervisory computer
system.

 Programmable logic circuit(plc):-these are also connected to the

 supervisory computer system.and it is used to control machines and
processes. It continuosly monitor the state of input device( proximity
sensors,contacts, push buttons and limit switches) and process it, in order
to control the output devices (valves,actuators, solenoids etc).

Plc and its working principle:-

1. Technically the PLC can be defined as "Digital Electronic device that

uses a programmable memory to store instruction and to implemented
specific function such as counting, arithmetic, timing, sequence, and
logic operations to control machines and processes". PLC is used as
industrial computer as heart of industrial automation. Basic PLC
components are shown infig below.

Following are the key features of plc:-

 As the program is predefined.plc generally work only in automated

mode.if there is any kind of error during the operation,the operation
cannot be proceed till it rectifies or corrected.

 The set point is predefined in plc cannot bealtered and needs a

 licensed program in order to make changes.

 In plc system there is no display unit due to which we cannot monitor

what is going on during the execution of a process.

 he languages to program plc is

1.Instruction List
2.Structured Test
3.Ladder Diagram
4.Functional Block Diagram
5.Sequential functional chart

HMI in
coating

There are
three
reasons
for
hanging
issue or

malfunctioning of a hmi is:-

1. Lan1 or lan2 is not properly connected.
2. Lan switch is not working properly.
3. If the pc of hmi in sleep mode during the porocess.
 Due to this the production stops . so that it leads to loss of time and it
may become more expensive.

 To resolve this issue we have to kill the task by giving the commands in
the command window or terminal.by typing commands like tasklist \
172.29.117.29 \u administrator \p drl@134. Such that a set of tasks
which we have to complete will appears on command window. And then
again use a command like taskkill \172.29.117.29 \u administrator \p
drl@134. So that task will be begin again at same stage which we are left
in the process without missing of data format for manufacturing a tablet
nothing but batch data.
 This task killing procedure or code is given by the vendor(glatt, zenon).

 Hmi will be controlled by plc and pc .

 Actually we take the remote or login in to the server of plc in hmi.and

then we operate the machine accordingly.

 the zenon or glatt view software is installed in hmi for functioning .and
scada is plays a major role in the hmi where it collects the data from the
plc. And work on hmi.

 we have analog inputs to the plc such that it gives the digital output (as 0
and 1). On state represents “1”.and offstate represents “0”.

Merits of hmi:-

1. Alarms or warnings:-
An HMI can allow plant operators to view alarms and locate a malfunction
in the equipment, allowing them to react more quickly. Alarms can be
preventive, so the operator is alerted before the system reaches an
emergency level. Alarms can also track several different problems and
increase productivity by optimizing manufacturing processes.

2.reliable messaging:-
For faxes, pages and more, operators can depend onHMI messaging. As an
example,when a machine should be refilled because of a low fuel level, the
operator will be alerted automatically.
3.easier overall management of the plant:-
Using HMI technology, your company can also easily manage and carry out
recipes. The high-quality graphics of HMI systems provide realistic views of
a plant's operations so that operators can control the facility from central
locations. This also helps with any security issues. Now an operator
doesn'tneed to approach dangerous areas, and they can control the monitor
from another location.

4.Accurate testing with simulation:-

Plant managers can test equipment and devices easily through the use of an HMI with
simulation. Testing can be achieved in the office without any piece of equipment. This
function improves overall production and reduces startup time.

5.Cost reduction:-
A human machine interface can reduce operating costs by replacing
hundreds of selectors, pushbuttons, indicator lights and more. This means
the need for extra cables, panels and consoles is also greatly reduced.

6.improved communications:-
HMI can also improve communications throughout the facility by using
various types of equipment. This includes the use of:

 Ethernet
 Data Highway Plus
 DDE (Dynamic Data Exchange)
 Remote I/O
 Serial port

Demerits of hmi:-

1. Security:-

HMI software systems have long been considered secure from any malware
but with their connect-ability to the internet in these times, they pose a high
risk of hacking. A flawed HMI could be a gateway for hackers to crash
systems that may lead to loss of important security and confidential data.
2.Poor Interface Design:-

Most accidents involving machine and automobiles are attributed to human

error but when they are investigated in detail, it is often concluded that they
were in fact caused by poor designing of an HMI thus causing problems of
interaction between the machine and the operator. A poorly designed
interface can result in undesirable operational consequences and errors that
may have devastating impacts on safety and performance.

ROOT CAUSE ANALYSIS

 Root cause analysis is done to determine the main cause of the error or
problem caused during the process. The root cause for the hanging issue
of the hmi is determined.

 This can be determined by using a 5 why’s effective tool to identify the

root cause for hanging problem of a hmi.

 5 why’s tool is a set of 5 questions to reach the problem. Asking a

question is for the problem caused and answer it.

 Ask the question using why again and again repeatedly until we find the
correct root cause as below.

1. Why did the hmi is suddenly hanging?

A. `mainly three reasons :-

a) due to insufficient storage.
b) due to repeated using of touch problem in hmi.
c) because of not providing cooling as the machine get heated up.

2. why did this problem occured?

A. Due to human error

3. why did human error occured?

A. there is no sop for maintainance of hmi . For example cooling of hmi to

prevent it from heating.and also to provide sufficient storage for ram.
4. Why this sop is not prepared ?

A. sop will be prepared with reference to the vendor or machine

manufacturing company like glat.

5.why did we go for reference from the vendor?

A. Because it is built by the vendor company and they know the

funtionalities of the hmi.such that accordingly they will prepare the sop. And
also they will resolve the issue even after hanging issue occured By giving
the coding consists of set of commands to type it in command window for
task killing procedure as I mentioned above.

Conclusion:-
hence by using this root cause analysis procedure we can sort out
the problem before it happens. An this reduces the time consuming
for production. If the machine not works for some time then there
is some loss in production.

HOW TO TRANSFER THE PROGRAM FROM USB TO HMI

3. After some time one Download/Upload window will be popup on HMI
screen. And select the Download option among them.

YOU WILL OBSERVE POPUP WINDOW AS FOLLOWS

3. ENTER PASSWARD AS 111111

YOU WILL OBSERVE POPUP WINDOW AS FOLLOWS

4.
THEN
CLICK
OK
BUTTON

YOU WILL OBSERVE POPUPWINDOWAS FOLLOWS

5. NOW CLICK ON USBDISK

YOU WILL OBSERVE POPUP WINDOW AS FOLLOWS

6. THEN SCROLL DOWN TO FIND THE FOLDER NAME AS BELOW
7. ENTER OK AS FOLLOWS
8. WAIT FOR FEWSECONDS

9. IT WILL DOWNLOAD PROGRAM TO HMI

10. AFTER DWONLOADING YOUR WELCOME SCREEN WILLAPPEAR
11. REMOVE USB DRIVE