Finding the formula for agile and adaptable pharmaceutical manufacturing  Create excellence in plant construction and operation with a digital plant approach

Contents

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Introduction

Take control of your plant’s data

Maximize productivity without compromising safety

Bridge the gap between plant construction and operations

Summary

FINDING THE FORMULA FOR AGILE AND ADAPTABLE PHARMACEUTICAL MANUFACTURING

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Leading pharmaceutical companies in America are expanding capacity to meet this demand. Manufacturers need to move faster than ever to manage multiple, complex product pipelines— and they need to scale without missing a beat.

Doing this can help you get your innovations from the lab and into homes quickly and reliably, without compromising safety. But whether you’re building new plants or reconfiguring existing ones, you can’t foresee all the challenges that may disrupt your plans.

What you can do is ensure your teams are equipped to face those challenges with more agility. That way, they can stay competitive in the market by getting facilities up and running faster today. All while being ready for tomorrow.

Introduction Aging populations, growth in emerging markets, and the rise of personalized medicine are all driving increased demand for pharmaceuticals.

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FINDING THE FORMULA FOR AGILE AND ADAPTABLE PHARMACEUTICAL MANUFACTURING

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When your plant is digital from day one, your teams can collaborate more effectively and maintain momentum on design and construction schedules. Digital workflows also collect operations data that can be used to inform your facility’s design and construction phases. This can be key to bridging the gap between the construction and operations of your plant.

The objective is clear: to increase capacity in a way that enhances agility and efficiency, so you can monetize innovations faster than the competition.

Stay ahead with a digital plant approach A digital plant approach can help you become more agile.

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FINDING THE FORMULA FOR AGILE AND ADAPTABLE PHARMACEUTICAL MANUFACTURING

This e-book highlights three best practices to build in agility and efficiency as you expand your capacity:

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Take control of your plant’s data.

Connect plant construction and operations data to accelerate delivery of medicine to patients.

Optimize processes and people flow to maximize productivity without compromising safety.

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FINDING THE FORMULA FOR AGILE AND ADAPTABLE PHARMACEUTICAL MANUFACTURING

Without that, your teams may not be able to reconfigure production lines or respond to the demands of personalized medicine when there’s a change in regulation. This is especially true if, like 70% of manufacturers*, you still rely on manual data entry. Those teams are more likely to work with wrong, duplicated, or out-of-date information, leading to unnecessary delays.

Get ahead of your data

Once you take control of your plant data, you can ensure everyone involved in your plant’s lifecycle can collaborate in a connected data environment. This can reduce the risk of errors or potential rework as everyone can access the most up-to- date information in one place.

* Source: Manufacturing Leadership Council

Take control of

your plant’s data Controlling all the data from your plant’s design and construction can help optimize its operation. To do this, you must mandate that all project data is captured and formatted from inception and included in the turnover of your newly built plants.

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FINDING THE FORMULA FOR AGILE AND ADAPTABLE PHARMACEUTICAL MANUFACTURING

https://manufacturingleadershipcouncil.com/seventy-percent-of-manufacturers-still-enter-data-manually-2-37141/?stream=all-news-insights

Align your digital and business maturity

Introducing advanced technological solutions can deliver key business insights from within your connected data environment.

But doing this without knowing where you are in your digital transformation journey can lead to innovation shock or fatigue. For example, business teams may want to adopt a new data-intensive cloud-based process that can deliver insights, but without a properly staffed or prepared tech team, the solution may be more of an added cost than a valuable tool.

To evaluate where you are in your journey, Autodesk can help conduct assessments to determine your current level of digital and business maturity. You can then use them to establish a baseline to train your teams and continually find ways to improve.

1/3 of all poor decisions made during construction are a result of bad data. Source: FMI and Autodesk

The result: An ecosystem for agile manufacturing

• Improved collaboration

• Ability to react faster to market changes

• Optimized production

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FINDING THE FORMULA FOR AGILE AND ADAPTABLE PHARMACEUTICAL MANUFACTURING

https://construction.autodesk.com/resources/guides/harnessing-data-advantage-in-construction/

Visualize your plant

Simulations can use data from your digital twin to create and visualize 3D models that represent the look and behavior of your plant. Your digital model can pull in data from your operational systems at regular intervals or even in real-time. That way, you can always have an accurate picture of your operations—from the flow of materials on the production line to the current temperature of your machinery.

Optimize processes and

people flow to maximize productivity without compromising safety One of the biggest challenges digital plant owners face is increasing productivity without risking safety. Addressing that challenge, however, is easier said than done. That’s when simulations can be critical. When you utilize simulations and other analysis tools in your operations, you can more easily streamline processes and people throughout your plant operations.

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Test any future

You can also model ‘what if’ scenarios with Discrete Event Simulation (DES) and Computational Fluid Dynamics (CFD). Doing so can give your teams a risk-free environment to experiment with things like various production line designs or planning for unfamiliar conditions. You can even use it to determine the appropriate number of people needed to reach throughput goals.

Testing with simulations like CFD can also help you determine fluid interactions and transport phenomena essential to designing reactors, mixers, and pipelines critical to process quality and efficiency.

The result: Streamlined pharmaceutical production

• Better worker safety. • Fewer risks. • Improved company reputation.

A digital plant approach can improve forecasting accuracy by

85%. Source: McKinsey

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https://www.mckinsey.com/capabilities/operations/our-insights/capturing-the-true-value-of-industry-four-point-zero

However, these costs can be mitigated with a digital plant approach by streamlining collaboration and decision-making across multidisciplinary teams. With this approach, you can get medicines to patients faster and maximize ROI through:

Better communication

When teams work from the same source of truth, the full potential of your data can be unlocked. Working from a connected data environment will help your managers, engineers, and suppliers identify any problem areas up front, build more accurate forecasts, and even manage supply chains in one place. That can help avoid costly errors during construction, like having a column where your production line needs to be. And during operation, you can avoid unnecessary bottlenecks and rework like duplicated documents or out-of-date information.

Increased efficiency

Digital twins can help optimize plant operations. With a digital twin, you can use data from your construction process, as well as real-time data from onsite sensors and more, to continuously optimize plant efficiency. For example, when used in conjunction with BIM- enabled simulations of layout and design options on manufacturing throughput, digital twins can track actual operations data to ensure your designs help you achieve real-world results.

Bridge the gap

between plant construction and operations Operating a manufacturing plant accounts for approximately 80% of your lifetime costs*.

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* Source: Autodesk

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https://www.autodesk.com/design-make/articles/digital-factory

Improved risk mitigation

You can also use a digital twin to mitigate risk. For example, you can minimize downtime and unexpected failure by tracking the performance of your assets with simulations that predict when maintenance should be performed. This can help reduce unplanned facility downtime, improve production capacity, grow business revenue, and increase successful patient outcomes. You can even simulate ‘what if’ scenarios virtually, so teams can respond to market changes faster, since they may have more insight into the impact of any change.

Then, when an issue does arise, connected data and digital twin information can help you respond without hesitation. Digital models can help staff physically locate and reach assets flagged on other non-graphical Enterprise Resource Planning (ERP) or Manufacturing Execution Systems (MES). Digital objects and physical QR codes can also provide immediate access to critical maintenance and operation guides that might otherwise take days to find.

The result: Your plant is optimized

• Improved plant performance

• Faster time-to-market

• Fewer unexpected costs

A digital plant approach can increase productivity by up to

30%

and reduce machine downtime by up to

50%. Source: McKinsey

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https://www.mckinsey.com/capabilities/operations/our-insights/capturing-the-true-value-of-industry-four-point-zero

By investing in more agile approaches to plant design, construction and operation, you can face these challenges head on.

Controlling, connecting, and continuously improving facility data will help you increase productivity, improve margins, and optimize operational efficiency, so your innovative pharmaceuticals get to the patients that need them faster.

In summary Leading pharmaceutical manufacturers in America are focused on expanding their capacity to meet growing demand—all while mitigating challenges such as supply chain disruptions or regulation changes.

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