Smart factory technologies, processes, and methodologies are core components of Industry 4.0. Those technologies, processes, and methodologies have evolved during this fourth industrial revolution era. What can you expect in the coming 12 months and beyond? What are the smart factory trends that will shape the life sciences sector in 2025?
We are focusing this blog specifically on the life sciences sector for two main reasons. The first is the fact the starting point for life sciences sector manufacturers is very different to enterprises in other industries and sectors. The life sciences sector also faces unique challenges in key areas that include compliance and patient safety.
At NNIT, we believe the following smart factory trends will have the greatest influence over the life sciences sector in the coming years:
- Digital transformation and modernization
- Flattening the technology stack
- The rise of UNS
- Increasing convergence of IT and OT
- Transition from paper to glass
- Predictive maintenance
- Focus on skills
- Integrating supply chains
- Growth of servitization
- Cybersecurity
- AI
- Industry 5.0
Digital Transformation and Modernization
The life sciences sector has been more cautious than other global manufacturing sectors in the transition to modern technologies and the development of smart factories. Being cautious about change comes from the regulatory burden that life sciences sector companies must operate within as well as the potentially existential importance (and moral duty) to ensure patient safety.
While there is caution, market realities mean traditional life sciences sector business models must evolve. They must evolve to respond to patient and customer demand. They must evolve to adapt to changing regulations. And they must evolve to ensure manufacturing facilities remain profitable and competitive.
We are entering a phase in the fourth industrial revolution where the digital transformation of manufacturing operations and the modernization of production processes are business necessities. From integrating systems to digitalizing processes to implementing custom software solutions that resolve legacy equipment issues, everything is on the table.
Flattening the Technology Stack
A key component of the smart factory is the integration of systems and equipment to facilitate a seamless flow of data across the factory floor, vertically through the rest of the company, and both upstream and downstream the supply chain.
The traditional manufacturing software stack has served the industry well, but it is not best suited to the integration and unification required by the smart factory. Flattening the software stack, especially across the SCADA and Manufacturing Execution System (MES) layers, will increasingly become the option of choice for life sciences sector manufacturers.
The Rise of the Unified Namespace (UNS)
This trend follows from the previous one as the traditional approach to communicating data between systems and platforms is also out of date for the modern smart factory. UNS is viewed by many experts in the industry as the most practical, future-proof, and cost-effective solution.
A UNS architecture creates a single data environment and central data repository. It is highly scalable and facilitates the implementation of smart factory technologies and solutions.
Increasing Convergence of IT and OT
IT and OT (operational technologies) have traditionally been separate and distinct. As mentioned previously, the smart factory requires data to flow across the factory floor, through the supply chain, and across all units of the business. Therefore, converging IT and OT technologies, processes, and procedures is a necessity.
Transition from Paper-to-Glass
One of the big challenges for life sciences sector companies in the transition to a smart factory is deciding what to do next. The number of possibilities and the scale of the challenge can be difficult to process. It is also challenging to clearly define requirements 100 percent accurately at the outset of a project, and there are always concerns about return on investment and ensuring success.
A step-by-step process is often the best approach, where the transition to a smart factory is a journey over time. When using a step-by-step approach, the best first or next step is often to focus on an existing manual, paper-based process. The aim is to transform and improve that process through digitalization and automation/semi-automation. An example is automating batch execution and leveraging electronic batch records.
Transitioning existing production processes from paper to glass is a trend that will continue over the coming years.
Predictive Maintenance
Sensors and digital twins are proven, mature technologies that enable life sciences sector organizations to move away from traditional scheduled maintenance to predictive maintenance. Predictive maintenance offers significant advantages, including optimizing maintenance costs and minimizing both planned and unplanned downtime.
Focus on Skills
The introduction of new technologies, Industry 4.0 methodologies, and smart factory production processes delivers a wide range of benefits to life sciences sector companies. The smart factory is also changing the skills that are required to run, optimize, and manage pharmaceutical and medical device production facilities.
Companies in the life sciences sector will continue to adapt to changing skillset requirements by upskilling, reskilling, and cross-skilling employees. Companies are also partnering with specialist smart factory solution providers to bridge skills gaps.
Integrating Supply Chains
A core principle of the smart factory is breaking down silos to integrate systems, platforms, and equipment. However, the benefits of integration don't stop at the dispatch doors on the factory floor. Therefore, we can expect an increasing focus on integrating supply chains over the coming years.
Growth of Servitization
Servitization is where companies evolve their business models from being product-only to offering both products and services. Digital health solutions, sensors, the Internet of Things, and other technologies are being used by life sciences sector organizations as business models move into the servitization space. Changes in regulations also play a role, especially regulations that require manufacturers to monitor their products across the whole product lifecycle.
The growth of servitization will have an impact on the smart factory and how modernization solutions are developed and implemented.
Cybersecurity
Cybersecurity is a high-priority issue for most companies. Given the position of life sciences companies in the wider health sector, that high-priority focus should never slip.
In terms of the smart factory and modernizing production processes, cybersecurity factors will continue to be a top consideration. This especially applies when integrating systems and equipment, especially those not originally designed for the modern, connected world.
AI
Any smart factory trends list should include artificial intelligence, including when the focus is on the life sciences sector. Examples of areas where AI will influence production processes and business operations include:
- Supply chain planning
- Predictive maintenance
- Product quality deviation detection
- Combatting fraud
- Identifying market trends
Industry 5.0
The smart factory is part of Industry 4.0 but the fifth industrial revolution, Industry 5.0, is on the horizon. The exact impact of Industry 5.0 technologies, strategies, and processes is still to be determined, but it is cantered on the intersection between humans and technology. Watch this space.
Continuous Progress Through Data Utilization and Process Improvement
In closing, many of the smart factory trends highlighted on this list involve more advanced data utilization and/or the improvement of production processes. Both of these elements – data utilization and process improvement – are what the smart factory is all about. For companies in the life sciences sector, exciting times lie ahead.
