Emergency HMI Recovery – Packaging Line (Pharma Facility)

Client: SPI Pharma
System: FactoryTalk PanelView HMI – Packaging Line
Scope: Emergency troubleshooting, HMI replacement, system restoration

Overview

A critical HMI failure halted operation of a packaging line at a pharmaceutical manufacturing facility. The system relied on a FactoryTalk PanelView interface for operator control, and the failure required immediate response to restore production.

Response & Execution

• Responded onsite within 2 hours of initial call

• Diagnosed failed PanelView unit and identified available spare hardware

• Upgraded firmware on replacement PanelView to match system requirements

• Successfully downloaded and restored the HMI application

• Brought the packaging line back online within 24 hours

Outcome

• Minimized production downtime on a critical packaging line

• Restored full operator control with validated system compatibility

• Ensured a controlled and reliable transition to replacement hardware

Follow-Up & Documentation

• Delivered a detailed technical report outlining:

  • Firmware upgrade procedure

  • Application transfer process

  • Configuration considerations for future replacements

• Provided the client with a repeatable process to reduce risk in future HMI failures