What you will learn from this article:
- Key opportunities to streamline life sciences manufacturing execution and batch records
- The role of unified data in making informed decisions
- Ways to support standardization and address cybersecurity needs in life sciences manufacturing
In life sciences manufacturing, speed means very little without accuracy, and the same can be said in reverse. There’s a perfect storm that manufacturers face, one defined by supply chain uncertainty, complex compliance standards, increasing demand for advanced therapies and devices and constant pressure to deliver faster than ever, all without sacrificing quality.
These competing demands require a competitive edge, and that comes from digitally unifying manufacturing, quality and facilities so that teams can act with confidence and agility.
When done right, digitalization transforms how people work, helping to reduce human error, enabling near real-time visibility and connecting siloed data into a single source of information. Here’s how the shift plays out.
Speed for Innovation
Digitalization makes its mark on speed. To shorten the road from promise to commercial product, digitalization can eliminate the friction that paper and manual workflows add to the manufacturing process.
Before
A single biotech batch record can involve anywhere from 5,000 to 45,000 manual entries, according to a McKinsey analysis. Every manual entry carries more risk than its digital alternative, and every error takes time and resources to correct. With so much room to make a mistake, even the most disciplined teams may see accuracy drop to around 91 persent, according to the same McKinsey analysis. That margin of error can result in product recalls which can cause safety risks to patients, delays on product delivery and innovation, and overall increased operational costs. Paper trails also slow tech transfer time and the time it takes to scale as each new site has to interpret and replicate processes without real-time clarity.
After
Digitalization can help alleviate those bottlenecks. A modern manufacturing execution system (MES) automates batch records, digitizes and stores recipes, and helps with inventory tracking and production monitoring all while digitally enforcing procedures. Data that once took hours or days to compile is available in near real time and ready to be accessed. The process itself is standardized which in turn reduces room for error.
Data Driven Insights Enable Smarter Decision-Making
Speed isn’t the only thing that life sciences organizations stand to gain through digitalization. When data gets moved from spreadsheets and into digital platforms, manufacturers are able to use that data to gather insights into how to optimize their processes.
Before
When systems are disconnected, quality data often arrives after problems occur. This makes way for a reactive mindset when handling deviations, where equipment failures dictate downtime, and facility systems like HVAC or security function in silos. The result? Delayed responses, higher costs and a constant sense of playing catch-up. As a result, organizations without digital solutions may make decisions without access to timely or reliable information.
After
With the help of a unified platform, quality management data is harnessed into one spot, allowing teams to collect, analyze and act on information presented in near real time. Predictive tools change the reactive mindset to proactive, with machine learning models that, according to Deloitte research, can reduce downtime by up to 15 percent and improve equipment effectiveness. Virtual models of assets and processes make it possible to align workforce capacity, material availability and equipment readiness with demand. Even facilities become smarter, as building domains such as environmental controls, fire systems, and security connect through open IoT platforms. Teams gain map-based visibility and can trigger automated workflows that help to shorten response times and reduce errors.
Connected Data Drives Continuous Improvement
Connection brings speed and insight together to form a consistent foundation that can allow organizations to capture, share and build on improvements across every site.
Before
Disconnected systems make continuous improvement difficult. Each site manages its own upgrades, templates and training. This often leads to different approaches where valuable insights get trapped in silos. Cybersecurity for operational assets can lag because Operational Technology (OT) and Information Technology (IT) are different, and tools built for one are not interchangeable with the other which can leave blind spots and lead to costly breaches.
After
With standardized systems and templates, organizations can move faster by accelerating tech transfer, simplifying upgrades, and reducing training requirements across global operations. A unified digital ecosystem also helps teams work with minimal disruption, whether the goal is modernizing an existing facility or bringing a new site online. This kind of connection breaks down silos so that information flows freely.
This also applies to cybersecurity. With continuous monitoring across manufacturing processes, quality management manufacturing execution systems, and building assets, organizations gain clearer visibility, stronger asset management and near real-time threat detection.
Find out more about how life sciences leaders are using digitalization to reimagine their entire operations - read our Unlocking the Future of Life Sciences Manufacturing eBook here.
