Four technologies that boost productivity in pharma

Speed, efficiency and quality are critical elements of success for manufacturing companies.

This is especially true for pharmaceutical organizations that have to deal with intense competition while adhering to strict regulations and face severe consequences for any mistakes.

In a report published in November 2021, Brian Curran, senior vice president of manufacturing excellence customer success at MasterControl, told Pharma IQ: “As buyers expect a wider range of product choices at a high quality, manufacturers must be able to respond to market demands and fast.”

There are several technologies that can enhance an organization’s ability to deliver with speed and efficiency. We have summarized the application of technologies in the pharmaceutical industry and assessed their efficacy.

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Automation

The benefits of automation have been extensively discussed on PEX Network and so it is no surprise it is one of the top technologies for manufacturers.

Delegating tasks to machines, which can work 24 hours a day and do not have the capacity for human error, has obvious implications for the speed and efficiency of a plant.

Many organizations have recognized these advantages and some, such as Beckton Dickinson, one of the world’s largest manufacturers of pre-fillable syringes, have even gone as far as the implementation of fully digital smart factories.

On the implementation of its first fully digital facility in Zaragoza, Spain, Eric Borin, worldwide president of Beckton Dickinson pharmaceutical systems, said: “This new plant will add needed capacity to support major vaccination campaigns, such as the one currently taking place in response to the Covid-19 pandemic.”

Ali Seddiki, director general of investment and business climate for the Moroccan government, also expressed his support for the practice of automated manufacturing for pharma companies:

“A modular, automated site is the fastest way of growing the ecosystem. The idea is to maximize efficiency and produce very fast. Automation and artificial intelligence are now the standard, even at our domestic pharmaceutical manufacturing companies in Morocco we have seen the change between the older manufacturing plants and the new ones, deploying robots, data and not using paper has made a huge difference to yield.”

For more information on how automation can be enhanced with intelligent technologies, read PEX Guide: What is intelligent automation?

Data and analytics

In order for pharma companies to drive operational efficiency and productivity, it is first important to understand exactly how their plant is operating. To this end, prioritizing investment into the organization’s data-related capabilities can be seen as a critical first step to driving operational excellence in manufacturing.

Businesses can do this through the application of a centralized data repository which brings all of an organization’s data together so that it is accessible by anyone in the organization in a digital platform.

Shifting from paper-based processes that result in information being stored in silos to digital processes that automatically collect and share plant data, such as production cycle times or amount of waste across the organization is a key step for digital transformation.

This is a step that, according to MasterControl's Curran, many have not yet taken in the pharmaceutical industry, which is considered one of the most competitive markets for manufacturers:

“The vast majority, 70 or 80 percent of pharma manufacturing sites are still using paper,” he says. “We all know the problems with paper, such as data integrity and legibility.”

The Internet of Things (IoT)

Equipping a manufacturing plant with IoT involves installing sensors and trackers to generate real-time data that helps monitor the operation of equipment and the completion of production cycles.

Such a system ties in well with a centralized data repository that actively informs an organization in detail about how the plant is functioning. This real-time data can be applied to identify bottlenecks or opportunities to enhance efficiency as well as reducing downtime for machines.

It enables preventive maintenance, a process in which data from the IoT is analyzed to predict how long a machine can remain in operation before it will need maintenance. By completing this maintenance before an issue is even reported, the downtime of the machine is minimized.

Learn more about reducing waste in an organization by reading 12 essential Lean Six Sigma concepts and tools

Augmented reality

Augmented reality (AR) uses visual technology installed in a wearable headset to give real-time, data-based digital alerts to an operator walking in a manufacturing plant. The data is ideally drawn from a centralized repository connected to an IoT platform and offers visibility on which machines need maintenance or where stock issues might come into play.

AR can also improve the speed of operators involved in the production cycle by overlaying instructional information that guides them in their tasks, which enhances their speed and drastically reduces human error.

Aside from this, AR can also be applied for training purposes, overlaying directions and instructions for whatever task an employee is learning to do.

Are there any other technologies which you feel are critical for pharma companies? Let us know in the comments below.