The Virtual Twin Experience for Biomanufacturing

Disruption, innovation, and global connectivity are all reshaping how biomanufacturers deliver today's novel therapies - the virtual twin experience can help you transform your operations.

The Life Sciences industry has changed significantly over the last number of years. With a view to developing new, novel, more effective, quality, precision treatments, industry leaders are exploring new therapeutic areas and approaches, leveraging the latest technology advancements to gain the competitive edge and deliver sustainable scientific innovation.

As pharmaceutical manufacturing lines transition towards small batch production to produce precision medicines, manufacturers need to effect end-to-end manufacturing line optimizations to produce these therapies more sustainably.  To do this, manufacturers look to connect systems, people and data — leveraging digitalization, automation, virtualization, modeling and simulation and Artificial Intelligence (AI) and what we call the Virtual Twin. The Virtual Twin, is a digital replica of real-world pharmaceutical processes, products and plants from end-to-end.  When leveraged with a platform based approach, it delivers the agility manufacturers need with science-based tools that can be leveraged to develop novel therapies. Explore more about the Virtual Twin for BioManufacturing in the chapters below.

01 Resource Planning

Coordinate all plants to optimize full planning activities with the supply chain Virtual Twin experience. Using “What-if” scenarios, compare and  optimize planning based on world-class KPI optimizations and experience increased flexibility enabling adaption to demand fluctuations to ensure ontime delivery.

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Sales & Operations Planning provides a complete workflow and supports the full process of Sales & Operations - predicting future drug demand and optimizing the supply chain based on the forecasted demand input. 


Companies can;

  • Better forecast demand to deliver drugs on time to patients
  • Optimize supply contract considering the full value network: suppliers, CMOs & wholesalers
  • KPIs driven S&OP Execution for a better drug operational management


02 Build & Simulate

Define, develop, optimize and validate recipes and the associated industrial setup by building the Virtual Twin of the manufacturing environment. Improve production flexibility with “What if Scenarios” to simulate, and analyze multiple production and process engineering scenarios, in a realistic 3D environment, optimizing the production workflow and resource utilization.

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Recipe Lifecycle Management allows to author, test and release new recipes faster using lifecycle management capabilities and therefore reduce time to market and ease recipe development in a sustainable manner.

Companies can:

  • Support the industrialization of recipes and their smooth transition to execution.
  • Access vertical knowledge and know-how about equipment and process 
  • Assess environmental metrics of the complete and configured manufacturing definition

03 Operate & Control

Effectively manage and achieve manufacturing operational excellence with the Virtual Twin experience. Unify manufacturing operations with warehouse processes, and experience full continuity between recipe authoring and recipe execution on the shop floor and in QC laboratories to minimize waste. Quickly adapt and scale up the production with fast refitting of processes and layouts to deliver flexibility and improved overall equipment effectiveness.

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Lean Operational Management offers the ability to digitalize Lean Practices on the Shop-Floor. By leveraging big touch screens technologies, it enables Lean representatives to broadcast company Lean Practices and ease the animation of Shop-floor meetings between team leaders, its team and other support functions. 3Dlean helps in capturing and retaining institutional knowledge and intellectual property and manufacturing know-how.

Customers can: 

  • Digitize Lean Practices for your operational meetings
  •  Deliver full empowerment to your team
  • Create Digital Continuity across organizational barriers

04 Optimize & Predict

Experience process control and optimization insights based on simulation, real time data gathering and data prediction with virtual twins. Understand and monitor the process to improve quality, sustainability and increase yield. Ensure safe batch release by monitoring production to identify out of control trends before failures occur and provoke waste of materials.

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Batch Process Analytics ensures continuous production by identifying critical process parameters and quality attributes and monitoring production to identify out of control trends before failures occur.

Customers can;

  • Minimize non-value-adding manual tasks, 
  • Reduce the risk of errors and compliance, 
  • Promote process understanding and knowledge sharing to reduce process variability.

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