An Intro To Pharma 4.0: Implementing Industry 4.0 in Highly Regulated Industries
An Intro To Pharma 4.0: Implementing Industry 4.0 in Highly Regulated Industries
An Intro To Pharma 4.0: Implementing Industry 4.0 in Highly Regulated Industries
While new technologies have multiplied opportunities for process improvements, regulatory oversight has
slowed adoption relative to other industries. Stringent requirements for documentation, data integrity, and
process validation all create an environment where compliance can outweigh continuous improvement.
Nevertheless, manufacturers who act smartly and decisively can benefit. There are more tools for improving
quality and efficiency than ever before. Many even promise to make compliance an automatic, seamless part
of the quality process.
This guide provides a comprehensive overview of digital manufacturing for the pharmaceutical industry.
Throughout, we’ll review use-cases, technologies, and strategies for applying digital technology that you can
use in your operations.
This is your roadmap for building digital capabilities in highly regulated industries.
In practical terms, it means more connectivity, more productivity, simplified compliance, and the marshaling
of production information to respond to problems as they emerge.
The term was coined by the International Society for Pharmaceutical Engineers to envision a digitally mature
pharmaceutical industry.
The ISPE’s digital maturity model for Pharma 4.0
The ISPE’s plan is holistic, outlining priorities for business, IT, and manufacturing throughout a drug
product’s lifecycle.
Their conviction is that digitalization will help organizations achieve “business goals by operating faster,
reducing costs, and being more competitive and agile”.
More than just an approach to digital technologies, Pharma 4.0 is also a means of transforming the
manufacturing workforce. From connecting workers to more human-centric workflows, to shifts in company
culture, humans are at the core of Pharma 4.0.
“[To] Manufacture pharmaceutical products with maximum product and process understanding, data integrity
by design, efficiency and optimal resource allocation on the basis of full digital data transparency–to the
benefit of the patient.” -ISPE
Pharma 4.0 Mission Statement
Many of the key points in the holistic model, however, are directly applicable to manufacturing.
Pharma 4.0 envisions a manufacturing paradigm that allows manufacturers to change and iterate, that
connects resources and workers, and that ultimately produces more quality product with better patient
outcomes.
We’re far from a reality in which pharmaceutical manufacturing lines detect problems and self correct.
Still, this trajectory from a baseline of digitization and connectivity to sophisticated, predictive systems is one
that manufacturers can take steps to achieve now. Indeed, with the right strategy, that future might not be so
far away.
Pharmaceutical manufacturers can realize significant gains by finding small opportunities for digitization and
beginning there.
Bringing Industry 4.0 To Pharma
Outlining a strategy for digital transformation isn’t a trivial task. Nor is finding small, scalable opportunities for
improvement.
Now, with a destination in mind, the question becomes: How do we get there?
The answer is adopting an agile approach, privileging a steady evolution rather than a rapid revolution.
The other is cyber-physical systems (CPS). CPS are networks that combine human and machine inputs to
create better communication and support between the different actors in a factory. In simpler terms, CPS are
connected systems that help support humans on the shop floor by contextualizing their activity across the
digital and physical domains of manufacturing.
IoT moves from centralized, hierarchical control models to distributed, emergent models.
CPS helps people make better decisions, find new opportunities for improvement, optimize the allocation of
resources, and improve quality by creating more responsive working systems. With, CPS, humans work
hand-in-hand with digital manufacturing systems.
Cyber physical systems (CPS) usher in a new era of efficiency by integrating humans within the manufacturing environment.
Emergent Control
Together, IIoT and CPS enable a bottom-up approach to pharmaceutical manufacturing. Hierarchical control
models require more information before implementing changes. With IIoT and CPS, control is emergent.
How are Industry 4.0 and Pharma 4.0 different? Here’s a breakdown of the key similarities and differences.
By emergent, we mean new patterns emerge as digital systems operation. Specifically, the increased
quantity and quality of information enables manufacturers to identify local problems in real-time, and to adapt
their improvements accordingly.
Accepting emergence means accepting that we can’t have all of the answers prior to letting the system run
and sampling its output. Working with emergence is key to creating value through evolution, not revolution.
Data Integrity by Design
Data integrity is one of the areas where Pharma 4.0 can contribute the most. Indeed, the ISPE outlines “Data
Integrity by Design” as the desired outcome of digital maturity.
Nevertheless, documentation in the pharmaceutical industry is often paper-based and error-prone. Lack of
standardization leads to data loss between research, validation, and production stages, and masks areas for
process improvement. During manufacturing, engineers record machine states, batch information, and
production schedules in paper forms. These logs are prone to transcription error, are labor-intensive to keep,
and difficult to reference. Often, mistakes are caught too late, at the end of a process.
With Pharma 4.0 solutions they are caught in real-time. This makes it possible to manufacture with a Right
the First Time approach and saves time in exception handling.
Traditionally, changes have been large, and solutions comprehensive. This required marshaling a significant
amount of organizational resources and energy around large, multi-year projects.
With Pharma 4.0, improvement projects need not be massive, costly endeavors.
It’s better to think in terms of localizable solutions that can be implemented quickly and scaled as necessary.
Many manufacturers, for example, might want to improve quality, decrease process variability, improve data
integrity, and simplify complex processes like line clearance and machine changeovers. Trying to solve each
of these problems with a single, top-down solution can lead to reduced efficacy in each area.
Modern Pharma 4.0 solutions work within broader quality management and manufacturing execution
systems to give manufacturers a faster, more flexible means of approaching improvements. They can be
configured and deployed quickly, and iterated as processes and target improvements change. What’s more,
they automatically collect data while they run, helping to provide the holistic physical/digital picture of
production necessary for the largest steps forward.
Because these logs are digital, they can be easily accessed to prove compliance.
Electronic logbooks make documentation and compliance reporting a seamless part of the manufacturing process.
Line Clearance
Many line clearance processes are complex, time-intensive changeovers. With paper-based processes,
workers may spend a significant amount of time looking for the next step or validating the execution of the
previous one and less time progressing through the procedure.
Interactive, digital line clearance applications can make line clearance easier to navigate. Digital, IoT-
enabled work instructions guide users through SOPs, increasing efficiency ensuring that work is performed
correctly and validated automatically. The applications record how long each step of the process takes,
improving process visibility, and enabling engineers to locate areas for process improvement. Because these
apps are collecting and communicating data in real-time, engineers can view process status as work unfolds,
leading to reduced downtime and more effective scheduling.
With Pharma 4.0, even complex procedures like line clearance can be made clear and simple. Digital work instructions replace paper SOPs and
ensure compliance.
Much of the labor spent in the review process comes from identifying incorrect or illegible entries, and
correcting records so that all production information is available for a given batch.
With electronic batch records, manufacturers can make data collection and validation a continuous,
seamless part of the manufacturing process. Information about manufacturing processes is automatically
collected as operators and machines work, and all data is thereby attributable, legible, contemporaneous,
original, and accurate.
When it’s time for a batch record review, the necessary information is accessible and easy to read.
Manufacturers can spend more time ensuring the quality of a product and less time correcting transcription
errors. With more data available, it’s easier to flag items to review by exception.
Process Visibility
In pharmaceutical manufacturing, the greatest barrier to process improvement isn’t always regulatory
constraints. In many cases, it can be a lack of process visibility.
With IoT devices and human-centric manufacturing applications, manufacturers can break complex
processes into their constituent steps, creating a granular, picture of how workers perform on the line. The
applications let engineers track individual operators' performance at each step. This lets them identify
situations in which more training may be necessary. It also helps engineers differentiate between poor
operator performance and poor process design.
In our experience, many of these changes are incremental and can yield significant gains in quality and
efficiency without triggering an audit or requiring revalidation.
Further, manufacturers can simulate processes in production settings by running apps in an “offline” mode.
Here, training modules walk employees through a process and collect data on their performance, while
governed execution mode makes sure that learners don’t impact production.
One of the promises of Pharma 4.0 is the enhanced interpretation of the data collected throughout a
product’s lifecycle. With advances in AI and machine learning, systems are better able to parse and find
connections within large data sets.
This manufacturer had a difficult time tracking the progress of jobs through rooms while still complying with
FDA guidelines for process documentation.
The Solution
This manufacturer used a number of Pharma 4.0 tools to address this issue.
Tulip offered a lightweight means of improving visibility within a validated facility. Working with Tulip partners
who specialized in deploying technology in regulated environments, this manufacturer digitized processes
using a no-code manufacturing application platform. Instead of using magnets to track room status, the
manufacturer used no code databases and visual dashboards to monitor and display the status of each
room in real-time. IPads were placed outside of each room, letting workers log room status, and creating a
digital record of production immediately available for analysis.
Custom manufacturing applications make it easy to improve control and visibility over sensitive tasks.
When room status changed, the manufacturing application system immediately alerted the next team,
reducing wasted time between processes.
While this manufacturer scanned all necessary documents for compliance purposes, the information wasn’t
available to inform process improvements. With the new system, the information immediately helped to
identify bottlenecks. Given that this facility lacked the space for additional equipment, optimizing production
processes was essential for maximizing value.
In the end, this company was able to balance GMP compliance and continuous improvement.
These digital work instructions eliminated paper from the line, and helped to record execution and validation
data in the course of the cleaning process.
These tools reduced the process from 10 to 2 days and simplified reporting.
While the FDA and manufacturers both envision a world in which compliance is a lower touch, collaborative
exercise, balancing continuous improvement with compliance will remain essential for years to come.
The promise of Pharma 4.0 lies in its ability to unlock new potential for productivity and quality while making
compliance a seamless part of the manufacturing process.
Manufacturers who take the necessary steps to embrace a digital future now stand to benefit from seamless
compliance, but it need not stop there. By adopting a Pharma 4.0 strategy, manufacturers can increase
connectivity, efficiency, and agility.
Improve quality and simplify