Last Updated on November 15, 2022 by Ossian Muscad
Biotechnology and pharmaceutical manufacturers are under immense pressure to bring products to market quickly while ensuring safety and quality. At the same time, they must do so in a highly regulated environment. That’s why it’s important to understand the concept of Pharma 4.0.
As the pharmaceutical industry moves into the fourth industrial revolution, or Pharma 4.0, manufacturers are looking for ways to apply new technologies and concepts to their highly regulated businesses. But what is Pharma 4.0, and how can you make the switch?
This guide will answer those questions and more, giving you a roadmap to implementing Pharma 4.0 in your business.
What is Pharma 4.0?
Pharma 4.0 is a digital framework for adapting digital industrial technologies to the context of pharmaceutical manufacturing. It builds on the concepts of Industry 4.0, the fourth industrial revolution characterized by the rise of digital technologies and data.
Like Industry 4.0, Pharma 4.0 aims to increase efficiency and flexibility while reducing waste and costs. However, because pharma manufacturing is regulated by agencies like the United States Food and Drug Administration (FDA), additional considerations must be taken into account.
Pharma 4.0 was first coined by the International Society for Pharmaceutical Engineering (ISPE) in 2017. The society defined Pharma 4.0 as a “holistic operating model for pharmaceutical factories and supply chains of the future based on Industry 4.0 capabilities, digital maturity, and data integrity.”
Pharma 4.0 is the continuous, proactive sharing of information and process knowledge across the pharma value chain, from drug development to patient care. Through Pharma 4.0, pharmaceutical companies can achieve greater transparency and quality while reducing overall costs.
What are the Benefits of Pharma 4.0?
The concept of Pharma 4.0 is still relatively new, but there are already several benefits that pharmaceutical and life sciences companies are seeing. Some of the potential benefits that have been identified include the following:
Increased Quality
By digitizing pharma manufacturing processes and collecting data, companies can more easily identify process deviations and correct them in real-time. This can lead to increased quality and batch uniformity.
Reduced Costs
Pharma 4.0 can help companies reduce costs by automating manual tasks, minimizing downtime, and reducing waste. At the same time, the increased quality that comes with Pharma 4.0 can help companies avoid the costs associated with recalls and other quality issues.
Improved Compliance
Because Pharma 4.0 provides increased visibility into pharma manufacturing processes, it can help companies ensure compliance with regulations. Automated data collection and analysis can also help companies identify and correct deviations from standard operating procedures more quickly.
Greater Flexibility
Pharma 4.0 can help companies increase flexibility by enabling them to reconfigure their manufacturing processes. This could accommodate changes in product demand or quickly introduce new products to the market.
Improved Safety
The ability to track products throughout the supply chain can help companies improve product quality and safety. In addition, the automation of pharma manufacturing processes can help reduce workers’ exposure to hazardous materials.
What Technologies are Used in Pharma 4.0?
Several different technologies are being used or developed for use in pharma manufacturing, including:
Advanced Manufacturing Technologies
Advanced manufacturing technologies such as robotics and artificial intelligence are used in pharmaceutical manufacturing. These technologies help companies increase speed, accuracy, and flexibility while reducing costs.
The Internet of Things
The Internet of Things (IoT) is a network of physical devices, sensors, and software that can collect and exchange data. The IoT is increasingly important in pharma manufacturing, as it helps companies connect devices and share data in real-time.
Cloud Computing
Cloud computing is being used to store and analyze large amounts of data generated by pharma manufacturing processes. Cloud-based solutions help companies reduce costs and increase flexibility.
Big Data and Analytics
Big data and analytics are used to understand and optimize pharma manufacturing processes. Companies can identify trends and optimize their operations by analyzing data from multiple sources.
Steps to Pharma 4.0
Pharms 4.0 involves six key stages of digital maturity. Following these steps will help companies transition to a pharma 4.0 operation. These stages outline a path that you should follow to implement and utilize Pharma 4.0 effectively:
Step 1: Computerization
The first stage of Pharma 4.0 maturity involves introducing digital technology to automate simple manual processes. The goal is to pinpoint repetitive tasks better suited for automation. Computerization will also establish the basics for digital infrastructure.
Step 2: Connectivity
The second stage of Pharma 4.0 maturity involves connecting pharma manufacturing equipment and devices to the network. This will enable data collection and communication between devices. At the same time, it also lays the foundation for integrating IT infrastructure, business functions, and manufacturing.
Step 3: Visibility
In this stage, you will see substantial improvements in your pharmaceutical manufacturing operations. The connected ecosystem involving people, machines, and processes will create a significant digital record of production that you can then use to create smart, data-driven decisions in real-time.
Step 4: Transparency
With more data being collected, pharma 4.0 will allow for a new level of transparency never before seen in manufacturing. Every player along the supply chain will have access to the same data, enabling better communication and collaboration. These advanced analytics will help find opportunities for improvement that were previously anonymous and invisible.
Step 5: Predictability
Detailed production records will enable manufacturers to correct problems before they occur. This level of predictability and prevention will result in less downtime, fewer recalls, and improved quality.
Step 6: Adaptability
The final stage of maturity involves adapting Pharma 4.0 manufacturing processes in real-time. This will also be made possible by the continuous collection of data and the use of advanced analytics. Additionally, systems will automate themselves in anticipating problems, and in turn, they will initiate the proper action without human intervention. This will result in a leaner, more agile, and more responsive pharma manufacturing organization.
Implement Pharma 4.0 with DATAMYTE
Now that you understand the six stages of pharma 4.0 maturity, it’s time to start thinking about how to implement these concepts in your organization. With DATAMYTE and its Digital Clipboard, you have powerful automation software that can help create comprehensive workflows that will take your pharmaceutical manufacturing to the next level.
The DataMyte Digital Clipboard is a workflow expert capable of creating any Pharma 4.0 workflow you may need, from data collection to analysis to final decision-making. Additionally, Pharma 4.0 with DATAMYTE also offers the following benefits:
- Improved data quality
- Increased transparency and collaboration
- Reduced cycle times
- Reduced downtime
- Decreased costs
With its easy-to-use drag-and-drop interface, you’ll be able to create unique and effective workflows with just a few clicks.
So, if you’re ready to start your pharma 4.0 journey, book a demo with us today and see how DATAMYTE can help you take your pharmaceutical manufacturing to the next level.
Conclusion
Pharma 4.0 is the future of pharma manufacturing. But with that said, it’s important to know how to properly implement these concepts to realize the full benefits. By following the steps outlined in this article and using the DataMyte Digital Clipboard, you’ll be well on your way to Pharma 4.0 success. So get started now!
