The importance of analytics in pharmaceutical manufacturing

In our last article, we talked about the importance of data acquisition, contextualisation, and reporting on production data in pharmaceutical manufacturing. We now move on to discuss analytics. According to The Manufacturers, more than a third of manufacturing decision-makers (36%) cite a lack of available data and insights as their biggest frustration. Surprisingly often, decisions are being made by ‘gut-feeling’ and more than three quarters of decision-makers are still reliant on spreadsheets, despite the state-of-art technology available today.

While many modernised manufacturing plants have invested in collecting process data, the data only has value when combined with analytics to create “connected applications” that deliver value, such as, resolving a business problem like “how to reduce downtime on the production line.”

Manufacturing analytics provides awareness in real-time that empowers companies to improve productivity and profitability by leveraging the massive data stream generated by their production equipment. In pharmaceutical manufacturing, this can be hugely beneficial by providing actionable insights to plant managers and decision-makers across the company.

Broadly, these benefits can be categorised under five sections:

1. Process Improvements – use the contextualised historical data to perform historical analysis and establish critical parameters, identify patterns, and determine optimal process characteristics.

2. Improving Quality – leverage real-time data to react to events, avoid production deviations, and ensure process/product compliance with highest quality standards.

3. Cost Reduction –reduce operational and material costs based on the insights revealed in analytics.

4. Energy Efficiency – optimize energy consumption through elimination of anomalies and suboptimal operating modes for energy systems, cut energy costs and reduce your carbon footprint.

5. Added Benefits – these include reduced compliance errors, increased customer satisfaction, safer environmental protocols, and many more.

Selecting the right solution

Selecting the right solution is not simply a tick box exercise, i.e., does the solution claim to meet the requirements. Many solution providers will claim this. Do some research, as the right solution provider should also have a strong and proven track record of successful implementations within your sector.

In addition, consider how adaptable and customisable the solution is to your unique processes. Many vendors try to sell a standardise solution across multiple industry verticals, which may keep their costs down but results in a ‘one size fits all’ scenario and means the solution you end up with never quite works as you may have first envisaged it.

MePIS is a state-of-the-art set of modular software solutions originally built for digitalisation of pharmaceutical production. It includes several analytic modules which help you uncover and exploit manufacturing optimization potential – among them for operational excellence, process data management and energy efficiency.

MePIS PDM (Process Data Management) is an advanced software solution for managing and analysing process data. It allows you to compare time-series data with events, compare batches and produce advanced reports for better understanding of processes and detection of quality deviations. MePIS PDM supports the creation of custom production report approval workflow and has an embedded full audit trail. It is the cornerstone for comprehensive production analyses and for data integrity in the regulated pharmaceutical industry.

MePIS OPEX (Operational Excellence) is a cutting-edge software solution that forms the basis for improvements in manufacturing productivity. The platform enables users to uncover and address hidden losses in production. Importantly, it then allows instant communication among key stakeholders about events in production, which translates into shorter reaction times and improved cooperation. MePIS OPEX has all the key features of an OEE solution – quality, performance and any downtime experienced, and more – it can be upgraded with artificial intelligence (AI) algorithms for autonomous analyses and faster ROI.

MePIS Energy (Energy Management) is a state-of-the-art energy management software that enables efficient collection of energy consumption data and analyses for energy consumption optimisation. It supports automatic and manual data inputs and has a rich set of functionalities that allow advanced analyses with normalisations, calculations of specific consumption (per produced product) and others. It requires little training and can be adjusted for different stakeholder groups (e.g., department manager, facility operator). MePIS Energy has a powerful reporting tool embedded in the software, and can be also seamlessly upgraded with AI algorithms.

Metronik, the company behind MePIS, is a trusted and innovative provider of digitalisation and automation systems for the life science industry.

In the last two years alone, more than 200 life science production systems have been integrated to MePIS, providing state-of-the-art solutions in the areas of process data acquisition, process data storage, process data analysis, recipe management, operational excellence, Track & Trace, serialisation and aggregation, MES, advanced process control and BMS/AMS.

MePIS systems follow the principles of Industry 4.0 and are fully compliant with GMP and regulatory requirements (e.g. FDA, Eudralex). To find out more visit: https://mepis.eu/, contact us, or sasa.sokolic@metronik.si

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