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Industry 4.0 has opened new possibilities for the pharmaceutical industry. Also known as Pharma 4.0, these advances in digital manufacturing promise to make the production of pharmaceuticals safer and more efficient – and ultimately more profitable.
Manufacturers are using Tulip to unlock the benefits of Pharma 4.0 by building apps that leverage IoT connectivity and no-code logic to streamline the full value chain. Below are some examples of apps that pharmaceutical manufacturers can design to reduce waste, improve documentation, and increase efficiency.
Digital History Record
Documentation in pharmaceutical manufacturing is often a manual, paper-based process. In parallel with process execution, engineers still record relevant machine states and batch information in paper logs. These logs are time-intensive, prone to error, and not necessarily integrated into the proper records.
Manufacturers can use Tulip to design Electronic Logbook apps that eliminate documentation errors while shortening the process. These digital logbooks let engineers record and integrate data from equipment, machines, processes, and operators, increasing process visibility even in highly regulated contexts. Media-rich eLogs place events, reason codes, notes, and photos in a single log, increasing the amount of information available on a given run. This data is easily accessible from process-specific data tables, and electronic signatures ensure compliance.
Check out the Digital History Record App in the Tulip Library
Work Instructions App
With existing systems, kitting activities are prone to inefficiency and waste. Mistakes mean rework and scrap, and variable or customized kitting operations can present challenges for process optimization and inventory management.
Pharmaceutical manufacturers can use Tulip’s IoT enabled sensors to design work instructions apps that guide operators through the kitting process for single-use materials. Pick-to-light systems show operators which parts to pick and where to place them; break-beam sensors ensure they select the correct part; and connected scales and cameras inspect the kits for accuracy. Further, database integration tracks inventory information in real time, so manufacturers always have up-to-date information. This app can help guarantee quality in an error-prone task.
Check out the Work Instructions App in the Tulip Library
Line clearance ensures that equipment and work areas are free of products, documents, and materials from a previous process. As it stands, complex machine changeovers and paper-based process validation result in slow turnaround times. Without real-time visibility, it’s difficult to reduce line clearance time or complexity.
For manufacturers who rely on quickly moving between processes, a Line Clearance app can centralize SOPs and equipment documentation, making line clearance easier to navigate for all involved. Digital, media-rich work instructions guide users through standard processes, reducing operator inefficiency, and IoT connected devices can be programmed to automatically adjust to standard settings for different processes, ensuring accuracy every time. Electronic signatures and validations simplify compliance, and step-based logic records the time it takes to complete processes, giving engineers more granular data about process execution. With Tulip, operators can view and update the status of machine and work areas, reducing downtime.