Automation suppliers: who does what for the pharma industry

Flexibility, research and efficiency, IT/OT convergence, dialogue between communication interfaces such as OPC UA, integration with additional devices, Edge computing in which to install the necessary apps (also with AI) for the management of reports and for predictive maintenance, as well as secure connections on a number of levels, use of digital twins, cybersecurity: these were the themes covered by companies which, in various ways, offer automation solutions to the pharma industry.

Below we offer a summary of the observations of

• Andrea Robbiani (Smart Manufacturing Business Manager of Corvina);
• Matteo Uva (Director of Alliance & Business Development of Fortinet Security Italy);
• Giuseppe Cocco (Regional Manager South Italy Pilz Italia);
• Tieghi (Marketing and Communication ServiTecno);
• Fabio Petrinelli (Portfolio Consulting Professional, Siemens).

IT security. With regards to cybersecurity, the evolution of the European NIS Directive was highlighted, which will become operative in October 2024 (the new regulations provide for the obligation to report attacks and their impact). It was underlined how not everyone is aware of the problems in a phase in which attacks are targeted and clearly increasing. IT solutions often turn out to be insufficient, with weak cloud solutions. A lack of expertise, in this regard, was a recurring theme, but schools with a free training programme are catching on.

Everyone pointed out the need to rethink security systems, as OTs are very exposed to attacks, providing, ideally, for a reduced number of platforms that are able, in any case, to communicate with those present in the company. Given that the digital transformation covers the entire business chain, the need arises to involve people, avoiding digitalising where unnecessary, since it is not important to gather data as an end in itself, but to analyse it with the right processes, motivating people and, finally, choosing the right technologies. While firewalls are essential for protecting data, the access identification systems, also with RFID technology, add further security and safety, permitting access to the machine only to those who are authorised.

Advantages in production. But how much can be saved with "digital"? Thanks to Digital twins in a pharma company, the 11 months required to extend the line were reduced to 8, avoiding the preproduction phase. In addition, staff transfer costs were halved, and it was possible to anticipate the training of people even though the line was not ready. In the future, it will be possible to simulate the expansion of the line or also of the entire factory, discovering critical elements. Already today, with digital twins, it is possible to adapt a machine to an operator with a consequent reduction in accidents and occupational diseases, saving on insurance costs. With digitalisation, in the event of an attack, the OT layer can restart quickly, but it is essential to organize backups in times suitable for production and to trace the applications used in production. The story of Insud Pharma is interesting in this regard: the plan provided for 2 years to complete the setting up of a protection network for the 43 branches in the world; 8 months were enough to "cover" the investment, reducing connectivity costs by 80% and network closure by 75%; the times for a new installation were reduced by half, moreover. Finally, an inventory of all the devices present in the various sites was drawn up.

In another pharma company, during the revamping of the machines, given the very high costs, it was decided to bypass the PLCs, installing a new network of sensors; with digitalisation, software no longer used was, therefore, eliminated and it was also possible to eliminate the printing of reports, drastically reduce micro-stops of the machines (<5 min) with a consequent improvement in performances, plan an evolved maintenance strategy and study servitisation possibilities.