Enhancing Operator Access on Automatic Filling Lines

We recently had a customer reach out with a very practical request: to limit operator access on their HMI (Human-Machine Interface) for an automatic filling line. Their concern was that operators had visibility of engineering-level settings, which could lead to accidental changes and unnecessary downtime.

Our solution was to restructure the HMI so that operators only have access to the parameters they need for day-to-day operation — such as start/stop functions, product selection, and basic adjustments. Engineering-level settings, including calibration, advanced diagnostics, and system configuration, were locked behind secure access.

This approach offers several benefits:

• 🔒 Improved security – Prevents accidental or unauthorized changes to critical system parameters.

• ⚙️ Operational efficiency – Operators focus only on the controls relevant to their role, reducing confusion.

• 🛠️ Reduced downtime – Engineering settings remain protected, ensuring the system runs reliably without unintended interruptions.

• 📈 Better accountability – Clear separation of responsibilities between operators and engineers.

The customer was pleased with the outcome, as it not only safeguarded their equipment but also streamlined the operator interface, making it more intuitive and user-friendly.

We’ll be following up with a site visit to review the rest of their automation systems, ensuring that access levels are consistent across all HMIs and that their pneumatic and electrical systems are protected against similar risks.

It’s a great example of how small adjustments in system design can make a big difference in reliability and efficiency.