How Big Data is changing the game at Octapharma

Over the past two years, Octapharma has made significant strides in becoming a data-driven, digitally powered company. A key initiative at its production sites is the deployment of Advanced Analytics, utilising artificial intelligence (AI) to drive operational excellence, optimise production flows and parameters, as well as to improve yields across production lines.

“The implementation of Advanced Analytics has already delivered notable early successes - with measurable yield enhancements observed for intravenous human normal immunoglobulin at our production sites in Lingolsheim and Stockholm,” says Olivier Clairotte, Chief Production Officer at Octapharma. “Our ongoing objective is to systematically expand this advanced methodology across all our sites. As mapped out in the Octapharma strategy, this allows us to capture significant efficiency gains and further elevate our operational performance.”

Better understanding our production process

A strong believer in the transformative power of data, Director of Manufacturing Intelligence at Octapharma Luuk Seelen is convinced digital technologies will change the trajectory of pharmaceutical production. However, he also emphasises that human curiosity will remain essential for harnessing the full potential of these technologies.

Luuk and his team are laying the groundwork for a robust data platform in collaboration with Octapharma IT to support this digital initiative. “By relying on data instead of gut feelings, we aim to make more informed decisions, improve production efficiency by eliminating unnecessary variations, and gain a deeper understanding of our processes,” he says. “However, there’s a hype surrounding data, and digital and AI-based technology that we need to be mindful of.”

AI and human expertise

“The ability of AI to outperform humans in certain tasks has led to misconceptions about its capabilities,” says Samuel Hultqvist, Corporate Production Data Engineer at Octapharma. “Many people assume you can simply run a smart program through big data and find solutions immediately.”

The reality, however, is more complex. Beyond cleaning vast amounts of siloed and unstructured data and creating powerful algorithms to analyse it, production teams must also ask the right questions. Otherwise, as Samuel explains, the results can be as unhelpful as the famous answer (“42”) from The Hitchhiker’s Guide to the Galaxy.

High hopes

When the right questions are posed, data and digital tools can be transformational, and the MSAT team is already seeing this potential. “To thrive in this data-driven era, we need to adopt a mindset that embraces these tools and learns to work with them pragmatically,” says Lukas Rachbauer, Corporate Production Data Scientist at Octapharma. “Group wide, diverse teams are collaborating to make sense of AI data and implement practical improvements. This blend of technology and expertise ensures optimisation and enhanced production outcomes.”

As an example, Advanced Analytics is already predicting outcomes at the Lingolsheim, Vienna and Stockholm production sites by analysing thousands of parameters, such as temperature, pressure, and pH levels. “To determine protein content, Advanced Analytics identifies which factors are crucial and whether they’re set optimally. This data-driven approach allows us to make precise adjustments to improve product quality,” Lukas explains.

Another example is Advanced Analytics’s ability to detect subtle temperature shifts in solutions that human operators might overlook, or to uncover inconsistencies between equipment that should theoretically perform identically. “These insights are essential for refining our processes and ensuring greater efficiency and consistency in production,” Head of MSAT Volker Weimar adds.

Moreover, Advanced Analytics is dedicated to improving production efficiency by eliminating unnecessary variations. By streamlining operations and reducing inconsistencies, Advanced Analytics not only enhances product quality but also minimises waste - leading to increased productivity and profitability.

This approach helps identify patterns and potential bottlenecks, supporting more informed decision-making and improved process management. “We’re already gaining insights about aspects we hadn’t considered before, and in the long run, we may even fully optimise our production, based on data,” Luuk adds.

According to Corporate Production Data Translator and a key member of the MSAT team Felix Kaineder, "By pinpointing the most influential variables and factors, we can focus our efforts where they matter most." He emphasises that the goal is not to revolutionise operations overnight, but to continuously optimise and reduce variability. "This approach allows us to detect and address minor changes before they escalate," he adds.

A cultural change for success

Recognising that AI can often appear complex and enigmatic, Volker and his team at MSAT are eager to demystify the technology. “As with so many other new advances, the successful application of AI requires curiosity, persistence and a willingness to embrace continuous learning, together with a pragmatic mindset,” explains Volker. “By breaking down initial barriers and providing clear guidance, we hope to turn initial challenges into stepping-stones for success, encouraging the wider effective application of these tools.”

“This cultural and technological transition is essential, as it will ultimately help us fulfill our vision to advance human life and expand access to our therapies. I am confident that we will seize the opportunities ahead and leverage data and digital tools to drive medical innovation,” Volker adds.