Is Industry 4.0 really a game-changer for medtech? Here's eight ways it actually could be.

1 – Reducing errors

Industry 4.0 technologies can be implemented across the whole manufacturing process, but quality control is perhaps the step with the most potential for improvement. Using sensor technology, manufacturers can quickly identify the source of the problem, and thus reduce unplanned downtime.

2 – Monitor and improve performance

Predictive maintenance technologies can save time and avoid costly breakdowns in the long term – all from a one-off investment in technology. Algorithms and machine learning, such as those used by GE’s Brilliant Manufacturing software, can now anticipate when – and why – a machine is likely to fail. Jennifer Bennett, general manager for GE Digital’s manufacturing software initiatives explained: “Manufacturers are challenged to decide what to build, how to build it, where and when to build it, and how to efficiently maintain it. We believe that the key to optimising the full product life cycle from design to service is through analytics of data that has been traditionally locked inside corporate silos.”

3 – Go paperless

Going paperless could signal an improvement in regulatory conformance. Robert Kavanagh, business development executive at Irish medical device manufacturing specialist Seabrook Technology says: “Taking a look at the recent FDA figures on Non-Compliance Observations, it is clear that production and process controls are a key source of issues. In our experience, over 50% of non conformances are a result of errors on paper, rather than problems with the product.”

4 – Track and trace

Raumedic is one of the major players in the medical device field to take steps towards going digital with its manufacturing systems. Last year the group selected software provider Guardus Solutions to design a new manufacturing execution system (MES) for its existing machinery as well as future investments. As a result, products from Raumedic can be tracked all the way back to the raw material and can also be cross-linked, managed and documented from the time of their development to their delivery.

5 – Bolder designs

Design trends like miniaturisation create opportunities for the medical device sector – but they also create challenges for manufacturers. Using advanced scanning and technology processes, manufacturers can produce more complex and intricate designs.

6 – Inventory controlIndustry 4.0 may be capable of increasing outputs – but more output means more raw materials and supplies coming into the plant. Luckily, technology could hold the key to this as well. Gelston Howell, senior vice president, marketing at medical device manufacturer Sanmina says: In the past, managing inventory was manually transacted in an enterprise resource planning system, such as Oracle or SAP. With the implementation of industry 4.0 technologies and the use of machine-to-cloud communication, inventory management has moved from manual to automatic transactions, enabling real-time inventory control.

7 – Customisation

Personalised medicine could be a game-changer in healthcare delivery – but it will have an impact on those manufacturers who aren’t geared up to deliver on the promise. 3D printing is one option, but older manufacturing methods can also be adapted with advanced product lifecycle management (PLM) software. For example, Siemens now offers a PLM platform that creates an automated image to implant process.

8 – Scalability

Adopting Industry 4.0 tech can help future-proof OEMs for future expansion. B. Braun Medical recently made the switch to a digital manufacturing system. Francisco Almada Lobo, CEO of critical manufacturing said of the move: “Critical manufacturing is committed to B. Braun’s success, both in our project execution approach and our flexibility to meet all of their long-term needs. We will use a joint project team to configure our system and build the competence to maintain it for the foreseeable future. We are confident that we will help B. Braun Medical Industries become a global benchmark for advanced and innovative medical manufacturing.”