In today’s fast-paced manufacturing environments, operational efficiency isn’t just a goal—it’s a requirement. From pharmaceutical formulation to food and beverage packaging, plant teams rely on real-time data, user-friendly interfaces, and streamlined alarm systems to keep processes safe, compliant, and on schedule. At the core of this digital infrastructure lies SCADA and HMI development.

While off-the-shelf platforms provide a foundation, custom development ensures your control system works exactly the way your plant operates. In this blog, we explore what goes into effective SCADA and HMI design, including best practices in interface design, alarm management, recipe control, and GAMP5 compliance.

What Are SCADA and HMI Systems?

• HMI (Human-Machine Interface) refers to the graphical user interface that operators use to interact with machines and processes—think touchscreen panels, dashboards, and control windows.
  
• SCADA (Supervisory Control and Data Acquisition) extends that interface with data acquisition, real-time analytics, historian integration, and control across multiple systems or facilities.

Together, they provide the eyes, ears, and control levers of your automated processes.

Why Custom SCADA and HMI Development Matters

Out-of-the-box systems often don’t reflect the realities of your plant floor. Poor screen layout, confusing navigation, and unprioritized alarms can lead to operator errors, slower response times, and unnecessary downtime.

Custom development gives you:

• Tailored functionality to match your process workflows
• Improved usability with operator-specific layouts
• Integrated compliance with regulatory standards (e.g., 21 CFR Part 11, GAMP5)
• Faster troubleshooting through smarter alarm filtering and diagnostics

Best Practices

1. Design with the Operator in Mind

Operators are your front line—and your interface should reflect that. Good design starts with understanding their needs, environment, and daily responsibilities.

Key considerations:

• Consistent layouts: Keep screen navigation intuitive and standardized
• High-performance graphics: Use grayscale elements with color only for alarms or critical actions
• Contextual information: Show only what’s relevant for the task or equipment at hand
• Responsive design: Touch-friendly controls and scalable views for different screens

Tip: e2i follows ISA-101 standards to ensure human-centered HMI design.

2. Alarm Management That Supports Action

In complex facilities, operators can be overwhelmed by alarms—especially if many are nuisance or irrelevant. Effective alarm management improves safety and performance.

Best practices:

• Prioritize alarms by severity and urgency
• Group alarms by equipment or process area
• Use clear, concise messages with action instructions
• Integrate alarm rationalization and audit trails

Tip: e2i helps clients conduct alarm audits as part of HMI upgrades to reduce noise and improve response.

3. Recipe Control and Batch Management

For industries like pharmaceutical and food production, batch control and recipe management are essential. Your SCADA/HMI system should allow operators to select and execute validated recipes—while logging all critical parameters.

Core features include:

• Secure, role-based recipe editing
• Automatic loading of setpoints, timers, and logic
• Integration with MES or ERP systems
• Batch data archiving and reporting

Tip: e2i develops secure interfaces with version control and electronic signatures for regulated environments.

4. GAMP5-Compliant Development

If you work in life sciences or regulated industries, GAMP5 guidelines for software development are non-negotiable. Your SCADA and HMI platforms must be documented, validated, and traceable.

e2i’s GAMP5 approach includes:

• User Requirements Specifications (URS)
• Functional and Design Specifications
• Software Development Lifecycle (SDLC) documentation
• Test case development and execution
• Change control procedures

Tip: GAMP5 compliance isn’t just about passing audits—it’s about building systems that are robust, reliable, and maintainable.

SCADA and HMI Platforms We Support

e2i is experienced with a wide range of platforms, including:

• Allen-Bradley FactoryTalk View SE & ME
• Ignition by Inductive Automation
• Wonderware InTouch & System Platform
• Siemens WinCC
• GE iFIX and Cimplicity

Whether your system needs a ground-up redesign or phased improvements, we tailor our development to meet your technical standards and operational goals.

Real-World Impact: Smarter Interfaces, Better Outcomes

Custom SCADA and HMI development helps manufacturers:

• Reduce operator errors and downtime
• Improve batch consistency and product quality
• Streamline training and SOP compliance
• Enable remote monitoring and centralized control
• Prepare for future growth with scalable architectures

For controls engineers, plant supervisors, and process engineers, these benefits translate to safer plants, happier operators, and more resilient operations.