How can digitalization help with the lack of workers in manufacturing?
One of the daunting challenges for industrial companies today is scarcity of qualified workforce in manufacturing. According to last year's survey by the Employment Service of Slovenia (ESS), 1 in 5 companies had to reject orders, while more than 10% of them postponed their planned expansion, and the same amount reduced production volume. Adding to the challenge is retirement of experienced workers, as their valuable knowledge and experience are key for efficient process execution.
Staff shortages in industrial companies are often compensated through overtime work or outsourcing, but neither of them is a sustainable long-term solution.
How can digitalization of manufacturing help?
Preservation and transfer of knowledge. In many industries, manufacturing data is dispersed among various databases, machines and spreadsheets, and sometimes even in paper records. The same goes for (most) procedures. Therefore, production planning, machine maintenance and operations’ stabilization largely depend on the “magic” touch of experienced workers, who possess the needed knowledge and intuition for proper process execution.
Digitization enables us to document their experience and convert it into algorithms, which combined with automatic data acquisition, processing and workflow help preserve practical knowledge. Thus, digital tools can become a virtual storage of knowledge for development of workers’ competencies and faster introduction of new employees, which enables manufacturing companies to maintain and increase their productivity despite workforce fluctuation.
More attractive jobs. A common (mis)perception is that work in manufacturing is monotonous and based on proven, but mature technologies. Therefore, such jobs are often viewed as less attractive for the generations that grew up with smartphones and tablets.
Digital solutions help us create a more technologically advanced work environment, where repetitive processes are automated and thus workers’ time is dedicated to more complex tasks for managing process stabilization and efficiency. Thus, jobs in manufacturing can become more interesting even for younger and more educated personnel.
Development of existing employees. In introducing digital tools, we must be careful to avoid partial implementations on the one hand or too fast a dynamic on the other, as we can endanger the stability of manufacturing processes or cause resistance among employees who are used to existing ways of working.
For that reason, structured and gradual introduction of new technologies is essential for stable modernization of manufacturing, attraction of new employees and retention of existing ones. The basis for that is a carefully prepared digital strategy, which addresses both technological and human resource aspects.
Furthermore, it is also crucial that the introduced digital tools are intuitive to use, which helps new and existing employees to get up to speed fast while having a good experience.
How can we help you at Metronik?
At Metronik, we are specialists for automation and digitization of manufacturing processes –and we can help industrial companies in several ways.
Digitization is much more than a software solution for collection and processing of manufacturing data. It must be carefully and comprehensively planned, and thoughtfully put into practice to enable achievement of key goals such as productivity increase, cost reduction, process stabilization, quality improvement, maintenance excellence and the like.
Therefore, at Metronik we can offer technical and operational consulting for carving out a digital strategy and implementing it with the help of proven solutions. This way, we can ensure the fastest possible results with lowest possible disruptions in manufacturing.
With advanced manufacturing digitization platform MePIS, we can support industrial companies also with practical tools that help them achieve operational excellence, efficient management of manufacturing processes, energy efficiency, higher process stability and product quality, and other processes improvements.
Our solutions are based on more than 30 years of experience in automation and digitalization of manufacturing plants. Their modules are flexible and configurable, so they can easily be adjusted to cover specific characteristics/requirements of various industries, such as pharmaceutical, food, chemical, automotive and others.
The common characteristic of our solutions are intuitive and user-friendly functionalities that enable quick learning, introduction, and are easy to use.
For more information about how we can help you in your specific situation, please contact Mr. Vanja Tomažič at vanja.tomazic@metronik.si.
Avoid deviations, batch destructions and delays caused by human errors in recipe management
Errors and deviations occur in every manufacturing process. But when they happen in pharmaceutical industry, it means that people suffering from life-altering diseases, may not receive their medicine in time or not in the expected quality.
A typical area – which is often neglected – where errors and deviations occur, is the process of defining and setting the production parameters on the process equipment. In most pharmaceutical manufacturing sites, this process involves numerous activities of which many are performed manually and on paper (e.g. review and sign-off, versioning, storing, parameter inputting) – all while we know how such way of working exposes manufacturers to high risks for errors.
The most effective measure to mitigate such risks is digitization. By digitizing the defining and setting of production parameters, the process becomes bulletproof and error-free, what can achieve with our advanced software solution MePIS RM.
Find out more on: https://mepis.eu/solutions/mepis-rm/
MePIS Energy awarded certificate of compliance with the ISO 50001 standard
One of the pillars for efficient energy management in organizations and reductione of energy consumption is introduction of the ISO 50001 energy management standard.
Industrial energy consumption and associated environmental footprint are becoming more and more important to the wider society, including customers, hence they are becoming an important factor for competitiveness in the market.
The basis for effective energy management is energy information system, which monitors energy consumption in real time, enables execution of analyses and facilitates development of efficiency improvement measures.
In this context, we are happy to announce that our MePIS Energy solution has been awarded certificate of compliance with the ISO 50001 standard.
The audit was carried by the certification company TUV AUSTRIA CERT GmbH from Vienna, we completed it in cooperation with our Austrian partner T&G.
How to achieve rock-solid GMP compliance and boost process efficiency at the same time?
The case for comprehensive reporting and process data analytics software
Proper management of process reports is crucial for GMP compliance. That is why there is no margin of error, when reports are being prepared and handled. Without central software which is integrated with production machines, report preparation can become unnecessary lengthy and complex.
Extraction of PDF reports from each machine can take a lot of time, and even when you get them, due to different formats, it is not easy to combine them into one understandable report, let alone make any other kind of use for the data – PDF is not really a digital format.
In advanced productions, the aim is to connect both – process reporting and data analytics – with structured data extraction from production machines through one central software solution. This way, they obtain raw and report machine data in useful digital format, which can be used for both purposes – preparation of full production reports and execution of analyses.
All this can be achieved through MePIS PDM, an advanced process data management platform that enables you to gather, organize and manage production data as well as generate comprehensive reports. Furthermore, with it, you can export the acquired process data into 3rd party systems – be it a BI tool, MES, or others; it can even notify external systems in case of inappropriate process data.
With MePIS PDM, you can achieve full process visibility, eliminate inefficiencies, prepare reports efficiently and not worry about audits.
Find out more about MePIS PDM and what it can do for you: https://mepis.eu/news/most-common-data-integrity-violations-in-life-science-manufacturing-and-how-to-avoid-them/
Innovative IIoT solution for higher machine uptime and lower operating costs
IIoT cloud platform is the result of R&D cooperation between Metronik and Telekom Slovenije
In an increasingly technologically demanding and competitive business environment, many industrial companies are looking for hidden reserves to improve business efficiency. An area with significant potential is the uptime/availability of machines, with analyses showing that with proper actions in this area, productivity can be increased by more than 10 percent.
Data on machine performance is a valuable resource for improving machine uptime. In the recent past, extracting this data and drawing any conclusions from it was technologically complex and expensive, but today, thanks to the progress of IIoT technologies (Industrial Internet of Things), this can be done much more easily and efficiently.
To achieve a leap in productivity, cooperation between machine manufacturers and end-users is necessary. Based on precise machine operation data, which we process into understandable information, it is possible to solve even the most demanding challenges, such as increasing machine availability by preventing breakdowns before they happen, achieving optimal ways of using machines and developing new generations of machines for greater efficiency.
All this can be achieved with the help of the cutting-edge IIoT solution for the acquisition and processing of machine performance data, which is powered by Metronik and Telekom Slovenije.
An efficient solution for machine manufacturers and users
The innovative IIoT platform enables data acquisition, transfer, storage, processing and display for monitoring machine performance and optimizing of operations.
IIoT platform consists of five key components, which are flexible and modular, offering manufacturers and machine users tailored solutions to their challenges:
- Core module: It ensures data extraction, preparation and transfer to a central cloud repository, as well as its processing into useful information, which users can also export to any third-party system.
- Operational Monitoring module: It is intended for the monitoring of machines, notifications for events, KPI calculations, analysis of efficiency and loss factors, and storage of all necessary operational documentation.
- Maintenance Support module: It provides comprehensive support for maintenance processes, including management of maintenance activities, history of performance and interventions, alarming, and storage for machine maintenance documentation.
- Advanced Analytics module: It enables the creation of customized reports for different needs, comparisons of machine operations at various locations, and the rapid investigation and elimination of the causes of failures, and it is the basis for additional services of machine builders (e.g. advanced maintenance).
- Artificial Intelligence module: The AI/ML module is intended for the most advanced users. It enables the adaptation of algorithms for predictive maintenance, digital twins and augmented reality and provides the latest technological solutions to specific machines and cases.
Throughout the whole cycle, the data is protected with state-of-the-art cybersecurity tools and protocols. Moreover, in the cloud, it is strictly separated per machine builders and users, and can only be accessed by users with the appropriate rights.
IIoT platform enables users to design unique displays or data overviews that differ from standard dashboards without any programming, as the application is fully configurable.
It is available through all standard web browsers and does not require any additional installation. It is accessible and adapted for all mobile devices, such as computers, smartphones, and tablets.
Benefits for machine manufacturers and end-users
With the IIoT platform, machine manufacturers can monitor machines in real-time and help users react quickly for better machine utilization and higher availability. Furthermore, they can provide new services and targeted machine upgrades. Data is also essential for faster and cheaper troubleshooting, machine maintenance and innovation/R&D.
Industrial companies gain a comprehensive overview of their machine operations, increase uptime/availability through faster reactions in case of breakdowns, and streamline production and maintenance processes, which reduces downtime and increases quality, stability and cost-effectiveness.
The innovative platform for monitoring and optimizing machine operations is the result of R&D cooperation between two leading companies in the fields of ICT and automation and digitization of industry.
Metronik is a leading provider for the automation and digitization of industrial processes, trusted by leading manufacturing and infrastructural companies in the wider European region.
Telekom Slovenije is a leading Slovenian provider of state-of-the-art ICT services and solutions, which is constantly developing and introducing innovative technological solutions to provide users with a superior network, state-of-the-art services, and an excellent user experience.
Join our webinar: Digital solutions for improved process data management, seamless reporting and in-process batch evaluation
According to different researches, more than a third of pharmaceutical manufacturing decision-makers cite a lack of available data and insights as their biggest frustration.
Moreover, disconnected data sources and applications in manufacturing disable comprehensive overview and control of key processes, and expose manufacturers to errors and deviations as well as data integrity and regulatory risks.
How can life science manufacturers mitigate that? How can specialized digital tools help?
Find out at our webinar, where we will explain in detail how pharmaceutical manufacturers can significantly improve process data management, achieve seamless reporting, and implement in-process batch evaluation with the help of advanced digital solutions that operate between process systems and MES.
What?
- Quick facts about Metronik
- Key challenges: process data management, reporting, data analysis
- MePIS: digital platform connecting process systems and MES
- A case study from a global pharma company
- Lessons learned and achieved benefits
- Q&A
When?
- Thursday, 6. October, 2022, 11-12 am (CET)
- Tuesday, 11. October, 2022, 2 -3 pm (CET)
Where?
Zoom – the link will be sent to you the day before the event
Who?
Saša Sokolić, Sales and Marketing Director at Metronik, more than 25 years of experience in life science manufacturing automation and digitalization
Who is it for?
The webinar is intended for managers and specialists responsible for production, IT, operational excellence or digital transformation.
Why would you participate?
You will learn about the importance and benefits of comprehensive data management in pharmaceutical manufacturing and the advanced technological solutions that make it possible.
Registration:
You can confirm your participation in the webinar at the links below; as the number of places is limited, we suggest you register soon.
Metronik strikes partnership with QM Consulting to bring advanced digitalization solutions to Polish life science manufacturers
We are pleased to announce that QM Consulting has joined our international partner network for distribution of MePIS Software solutions in Poland.
"Our team has extensive experience in the life science industry with projects in Poland and in the wider international environment. We are particularly specialized in the validation of computerized systems, audits of data integrity systems and quality systems, as well as in building and improving quality systems based on GMP standards", says the representative of the company, which is based near the city of Lodz, Marcin Kubiak.
With nearly 40 million inhabitants, Poland is one of the largest European countries and a correspondingly large market for pharmaceutical products and production.
With numerous successful automation and digitalization projects in over 30 years of Metronik’s operations, we are confident that we can bring significant added value to Polish life science manufacturers and help them improve management and control of their processes, increase regulatory and GMP compliance, identify cost-saving opportunities and develop optimization initiatives.
We are looking forward to the new partnership and we hope we will soon be able to share the news of interesting digitization projects in the life science industry in Poland.
6 strategic steps to enable a successful digital transformation of life science manufacturing
Digitalization of manufacturing operations is one of the most extensive and challenging investments for modern industrial companies. As a consequence, there are a number of options for co-financing these projects by the state, since improving production efficiency is one of the fundamental conditions for maintaining the competitiveness of the manufacturing economy.
However, research results by Gallup, show that even in developed European countries, more than 70 percent of digital projects in manufacturing do not achieve their set goals. Therefore, the question naturally arises, what are the key obstacles to a successful digital transformation of production, and how can we avoid them.
Given the above, a methodology has been developed to help managers in digital transformation projects, which includes six strategic steps:
1) Gap analysis and goal setting. Before starting a digital transformation, managers should identify the most prominent production gaps that represent key weaknesses or opportunities for process and productivity improvements. Then, benchmark these existing capabilities against competitors, industry standards, and best practices to derive to a set of goals for digitalization.
2) Creating and sharing a vision. Digital transformation often starts with executives, but loses momentum when it spreads to manufacturing employees. Therefore, it is necessary to convert the digital goals into a compelling vision that will be easily understood for every stakeholder in the company. If leaders fail to achieve positive expectations, digital initiatives fail because employees won't see the benefits and will resist changes.
3) Selection of priorities and measurable implementation of changes. Digital transformation often impacts several departments or even the entire company. Therefore, a properly planned approach to implementing changes is essential, as well as the appropriate inclusion and coordination of all departments involved. The plan should lay out clear objectives, stating what these are, how they will be achieved, by whom, and over what timescale, including external experts who can help with their practical experience.
Typically, companies select one or two priority digitalization initiatives and determine key factors such as timelines, measurable KPIs, and sufficient human and financial resources. Experience shows that starting digitalization with multiple initiatives at the same time can lead to confusion and does not achieve positive results.
4) Pilot projects. Before allocating more resources and implementing digitalization on a broader scale, it makes sense to conduct smaller and shorter pilot projects, to identify obstacles to success, organizational strengths and weaknesses and test capabilities. Pilot projects are also important for gaining experience, with the help of which digital initiatives can be implemented more easily and quickly in the remaining parts of the production process, in different locations, and perhaps even countries.
When implementing digital solutions, it is essential to have "quick wins," to gain the momentum, as projects with longer horizons lasting months or years often lose enthusiasm and become watered down. Agile methods allow us to do this. Firstly, they are naturally collaborative and consider different areas and points of view. And secondly, because with shorter work cycles, they identify obstacles more quickly and avoid them in time by adjusting the tactics.
5) Monitoring results. During and after the implementation of pilot projects, managers must monitor the impact of the new technology according to measurable criteria. The key is that the results are consistent with the planned goals. If this is not achieved, it may be necessary to change the approach and test again with a new pilot project, before wider roll-out of digital initiatives occurs, with more resources.
6) Roll-out. Once sufficient experience and feedback has been gained through pilot projects and they confirm the strategy's suitability, as well as reduce the risks of failure to an acceptable level, the digital transformation can be rolled-out across the business. If this doesn’t happen quickly, there is a likelihood that the enthusiasm for the results and the momentum will die, and the participants will return to their daily work and forget the lessons learned over time.
In summary, one of the most important factors for success is that management support and finance are sufficient to achieve the goals of digitalization. However, it is also essential ensure the commitment of employees as users of the digital solutions as well as everyone else who participates.
For a successful digital transformation of manufacturing operations, experienced partner is essential
Digital transformation is never easy, especially in times of rapid technological and business changes that constantly push the boundaries of what is possible and acceptable. It is even more challenging if most employees do not see the point or do not feel ready, and most challenging if the return on investment is not realized.
The main reason that two-thirds of projects fail to achieve their goals is that inappropriate planning does not consider the basic rules of implementing and managing change, such as the need to change working practices.
Therefore, it is highly recommended for all companies that are considering introduction of digital technologies in manufacturing operations, to work with an external partner who has the appropriate knowledge and practical experience.
At Metronik, we’ve helped more than 100 manufacturing companies exploit the benefits of digital transformation and gain confidence for more extensive production operations projects. With a mix of technological as well as operational expertise, we bring all the necessary capabilities for successful implementation of standard and tailored software solutions, and facilitation of the necessary change management in organizations to make changes stick.
For more information about the planning and implementation of digital solutions in manufacturing operations, contact Saša Sokolić, at: sasa.sokolic@metronik.si
Webinar invitation: Digital solutions for process data management, seamless reporting and in-process batch evaluation
According to different researches, more than a third of pharmaceutical manufacturing decision-makers cite a lack of available data and insights as their biggest frustration.
Moreover, disconnected data sources and applications in manufacturing disable comprehensive overview and control of key processes, and expose manufacturers to errors and deviations as well as data integrity and regulatory risks.
How can life science manufacturers mitigate that? How can specialized digital tools help?
Find out at our webinar, where we will explain in detail how pharmaceutical manufacturers can significantly improve process data management, achieve seamless reporting, and implement in-process batch evaluation with the help of advanced digital solutions that operate between process systems and MES.
What?
- Quick facts about Metronik
- Key challenges: process data management, reporting, data analysis
- MePIS: digital platform connecting process systems and MES
- A case study from a global pharma company
- Lessons learned and achieved benefits
- Q&A
When?
Thursday, 25th August, 2022, 2-3pm (CET)
Where?
Zoom – the link will be sent to you the day before the event
Who?
Saša Sokolić, Sales and Marketing Director at Metronik, more than 25 years of experience in life science manufacturing automation and digitalization
George Walker, Managing Director at iioTek, an independent Industrial IT & Automation consultancy
Who is it for?
The webinar is intended for managers and specialists responsible for production, IT, operational excellence or digital transformation.
Why would you participate?
You will learn about the importance and benefits of comprehensive data management in pharmaceutical manufacturing and the advanced technological solutions that make it possible.
Registration:
You can confirm your participation in the webinar at the links below; as the number of places is limited, we suggest you register soon.