When we envision the future of manufacturing in the pharmaceutical industry what do we see? We might describe factories, back offices and production lines across the globe fully integrated and optimized through smart manufacturing technology, empowered by AI and IoT systems.

There is no doubt this is an exciting vision. But how do we set about making it a reality? When describing the benefits of smart manufacturing we often outline them in terms of the direct interests of the organization, such as profitability, optimization, productivity, quality and efficiency, and place human level advantages as an ancillary consequence.

I believe we can look further and make our focus the impact these benefits could have for individuals and for the wider world. In particular, the manufacture and distribution of less wasteful, advanced, more effective and more affordable pharmaceuticals. In order to achieve these goals, we should make the positive impact for the larger global community our primary, not secondary, focus.

Smart manufacturing can help us break away from the old outlook and progress with making the world healthier, together. In this article I am going to examine seven key aspects of smart manufacturing; reframed with a holistic perspective.

Adopting to a digital mindset
There is still some resistance to technological change, but on the whole, and particularly as a result of the Covid-19 pandemic, most businesses and individuals are fully aware of the necessity and advantages of embracing technology. The pandemic certainly demonstrated how quickly we can adopt the digital mindset when necessary, but having made these changes, we need to ensure, moving forward, they permeate our lives in a positive way.

Smart manufacturing can help lead the way for transformation in our sector and have a far-reaching positive impact on the lives of many. Its systems are initially formed through the integration of IoT and AI into manufacturing and packaging processes. Useful data collected from sensors located in key positions on machines is collected and analyzed by AI systems. Data can be accessed through a secure user interface, facilitating the monitoring and management of machines from anywhere in the world. This creates a connected ecosystem of machinery, and allows for the possibility of accurate predictive and remote maintenance, as well as generating and analyzing data that can be used for optimization.

In order to realize the full benefits of smart manufacturing it needs to be utilized effectively. This comes through continued education, training and awareness, ensuring all involved from the ground-level up are on board with digitalization in the workplace, and investment is made in upskilling the workforce. Now that training and development can be done remotely via digital platforms, the process is far more accessible and manageable. Resistance to change can be countered by spreading awareness of the benefits—not just KPIs and metrics, but the advantages for all associates, as well as the impact better manufacturing can have for others outside the business.

Communication and collaboration
Smart connected machinery can communicate and inform operators exactly what remedial work it needs, even before it is needed. This means that machines don’t need to be checked and stopped unnecessarily, but embedded feedback mechanisms can provide alerts, via the remotely accessible user interface, to communicate issues, or potential issues, with a machine. The time and type of maintenance needed can then be decided based on assessment of the data and with the help of experts in the technology providers’ Network Operating Center. Depending on the situation, various options for maintenance are available to ensure efficiency and reduce downtime. These options include:

• Maintenance via remote assistance;
• Emergency parts changing for critical situations;
• Planned shutdowns; and
• Incremental interventions to spread out the maintenance process.

Unplanned breakdowns can be effectively prevented—offering manufacturers the potential for higher productivity and less waste.

Beyond the benefits of communication from machinery to enable predictive maintenance, the data collected through IoT systems, information available through AI, and digital data sharing in smart manufacturing will also ensure better collaboration with suppliers and customers. Instant, secure data sharing with selected stakeholders, or machinery providers, will allow those involved in the production and manufacture of pharmaceuticals to work more effectively together to make improvements for their businesses, as well as the consumer.

The potential is also there for technology to better the relationship between pharmaceutical companies and the end consumer. Smart manufacturing can be part of the solution to bridge this gap. Data can be used to develop transparency and trust, with accurate, real-time information collected during smart manufacturing processes guaranteed and communicated to the consumer. This can be done via QR codes on drug packaging, where consumers scan the QR code to receive an assurance of the legitimacy of the product and source. Smart manufacturing may also help with the advancement of active and smart packaging.

Data analysis and collection
Ensuring the ethical collection and application of data is a critical aspect of smart manufacturing. IoT can, and will, collate huge amounts of data that can better people’s lives. However, it is essential organizations have concrete strategies to ensure this data is used both effectively and responsibly.

Security
Data privacy is a fundamental issue in today’s world. IoT-enabled machinery and smart manufacturing software providers must ensure the customers’ right to privacy and security. This right should be guaranteed to customers through the integration of other technologies and multi-layer security measures, which could include the following:

• Blockchain
• Device registration and passkey management
• Isolated networks (VPN)
• Firewall integration
• Unidirectional data flow
• Encryption
• Proprietary PLC drivers
• STAR certification for the system

Any data that is taken and stored through a smart manufacturing system and platform ought to have been agreed to by the customer, with providers having a responsibility to clearly and openly communicate during this process. Decisions must be made, and agreements signed, to have data stored and taken, as well as the capability and parameters of said data. Sensors are only activated following customer agreement.

Capability
Companies providing smart manufacturing systems can work with their customers to ensure they have a full understanding of the capabilities of their sensors and AI analysis. The volume of data plays a critical role in developing the proficiency of AI platforms. Therefore, we need better educated users, ones who realize and agree to greater data usage because they have an understanding of how the information will be useful to them, but also how it can support the advancement of knowledge and build a healthier world. Having said that, all information must be collected for a purpose, and used for real world applications—not data collection for the sake of data collection.

Quality and safety
Data provided by sensors on machines, and analyzed by AI, may impact machine design and enable improvements from a health and safety perspective. There is the potential for machines to be redesigned to have safer access for workers and to be more easily fixed, cleaned and maintained.

Another way in which smart manufacturing may facilitate safety is through the security of data sharing, and the reliability of data gathered directly through sensors. The quality and safety of medicines can be better guaranteed by regulatory bodies as the information provided to them by manufacturers utilizing smart manufacturing technology is almost impossible to be tampered with.

Time and efficiency
Predictive maintenance, alongside increasing the flexibility and optimization of machines will improve efficiency for partners and businesses. Throughput can remain high, and rejected product minimal if maintenance is planned. Customers are less likely to experience delays with deliveries, therefore partnerships will flourish.

We need to bear in mind what the other purposes of achieving a better throughput are. Primarily, creating less waste and using less resources to reduce our impact on the environment, and ensuring the timely production of critical medicines for the health and wellbeing of millions around the globe. It’s also possible that the careful, data-empowered method of predictive maintenance, and avoiding ‘run-to-failure’ operations, could help extend the life of machinery, thus improving the sustainability and cost-efficiency of assets.

Another aspect of efficiency that can often be overlooked, but should really be at the forefront of business leadership today, is how it can reform the workplace for employees. The more informed and efficient maintenance available through smart manufacturing can help support the wellbeing of associates. Factory-level workers and maintenance teams will be working in a safer environment. They will also hopefully experience less stress as they will be able to make better informed decisions to make their work more productive, cut back on unexpected challenges, and reduce risk.

Additionally, eliminating delays caused by unplanned maintenance or product rejections from malfunctioning machinery will help supply chain and customer account managers because they will have to deal less with these unexpected issues, and the resulting frustrated stakeholders in the supply chain.

Cost
Predictive maintenance and optimization of manufacturing has significant cost and productivity benefits, with uptime improvements, OEE and less product waste. Ultimately, these improvements should result in cost reductions for an organization. The big question then is, what will be done with the profit gained?

Within each business we need to examine how the profits can be passed on and consumer costs reduced to make lifesaving medicines more accessible and affordable.

Advancing medicines
Smart manufacturing will help make personalized drugs an attainable large-scale reality. By reducing costs, as well as improving the flexibility of manufacturing through faster changing production lines and better awareness of the capabilities of machinery, these systems will enable manufacturers to produce more advanced, personalized medicines.

In the future, smart manufacturing could even transform the dispensing of medication and encompass the creation of customized medications, 3D printed or compounded by pharmacists, in front of the end customer. All of these developments are intended to create better, more effective, patient-centric medicines that make it easier to meet dosing regimens.

Conclusion
Smart manufacturing can help solve many issues faced by pharmaceutical manufacturers. However, when we look at its integration, we need to think not just in terms of individual locations or organizations, but have the larger picture and aim in mind from the outset. Our values are not focused on input and output, but how better operations and technology can facilitate ethical decision making and impact society.

The pharmaceutical industry should be focused on providing accessible, affordable, quality medicines for all. Whilst technology will play a large part in enabling the transformation of the sector, pharmaceutical manufacturers can lead the way by revolutionizing their outlook and building transparency, human capital and principles, and security into the heart of their operations. 

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With a background studying mechanical engineering, and an MBA in marketing from the K.J. Somaiya Institute of Management Studies and Research, Anand has been working at ACG for over a decade. In his role as head of sales for ACG Engineering in North America, he is working on making access to pharmaceutical and nutritional oral solid dosages better. He is passionate about generating technological and humanitarian progress in the pharmaceutical industry.