Real-time data exchange will require improved data quality and standardisation, interoperable data platforms, localised high-speed connectivity and improved cybersecurity. None of this will occur overnight, but increasing regulatory clarity has the potential to act as the catalyst for scaled-up manufacturing transformation in four key areas:
- Optimised production: machine learning and digital twins offer the potential to optimise production planning and conduct multivariate, in-flight tuning of production lines. Flexible production relying upon modular equipment for rapid re-configuration will increasingly become the norm for small-batch, personalised medications.
- Quality control and quality assurance: traditional QC and QA processes are labour intensive. By contrast, computer vision systems combined with deep learning algorithms enable continuous in-process output checks. In addition, AI can analyse deviation data to predict quality thresholds over time.
- Predictive maintenance: AI-driven monitoring systems can substantially improve maintenance inspection routines, reduce downtime and extend equipment lifespans.
- Compliance AI: the compliance burden in manufacturing plants will increasingly be streamlined by AI systems that exploit access to real-time data in order to generate compliance documentation.
Supply chains remain a target for upgraded technology
Four out of 10 executives in the sector expect the continuing supply chain disruption to act as a brake on growth this year, according to our global report: Strengthening supply chains. Significant investment in digital systems that improve operational agility is enabling better responses to geopolitical and climate change disruption (e.g. ‘what if’ scenario planning). In general, pharmaceutical companies are working to develop end-to-end visibility across their supply chains. However, incompatible datasets and legacy manufacturing systems used by suppliers frequently complicate the process.
“After Covid-19, risk management changed. The ideal supply chain in pharma became one that was ready to address any challenge, anywhere.”
Jacques Lambert, Senior Advisor, Life Sciences, Forvis Mazars Group
Clinical trials form a specialised part of the industry’s supply chain. Trials are costly, persisting for an average of eight years in the US alone, and can account for up to 70% of the cost of bringing new drugs to market. They require small-batch therapy production, specialised labelling, frequent use of cold-chain logistics and return pathways for unused drugs. Increasingly, AI is being used to select patients and run synthetic control groups. Patient attendance at a medical facility is no longer a necessity in all cases. Increasingly, home-based trials leverage remote sensors and telemedicine to reduce the need for travel. Depending on the circumstances, decentralised approaches like these may create a need for significant edge computing capacity, including reliable connectivity and the ability to secure patient data by maximising the amount of data processing conducted on site.
We recommend the following approaches to supply chain management system upgrades:
- Begin the drive to establish a single source of truth for supply chains by unifying isolated data silos across multiple systems. Digitise remaining paper-based workflows, clean datasets where necessary and impose data governance.
- Encourage adoption of cloud-based platforms that offer scalability, interoperability and real-time collaboration internally and externally with suppliers. Examine the potential of supply chain ‘control towers’ that enhance visibility and allow faster responses to supply chain disruption.
- Examine AI’s potential to improve demand planning by combining predictive analysis of epidemiology, sales data, demography and other external market trends.
- Shift to digital and machine-readable data for clinical trials. Examine AI’s potential to accelerate patient selection. Investigate the potential of remote monitoring, home care and telemedicine for decentralised clinical trials.
Managing real-time governance and regulatory lags
Deployed within autonomous AI agents, generative AI has the potential to transform compliance. Drawing on knowledge bases containing previous regulatory submissions, for example, AI has the potential to reduce re-submission requirements by identifying unsupported claims, tightening up language and anticipating regulators’ follow-up questions. It also seems likely that agentic AI will supplement the skills of compliance project managers, assessing timelines and the resource requirements imposed by impending submission deadlines.