Revolutionize your pharma training: Reduce errors and enhance learning efficiency with augmented reality

Augmented reality (AR) provides immediate access to in-depth expertise on advanced technical concepts. Time spent on training and education can be reduced by up to 25 percent while simultaneously preventing mistakes. This further step towards digitalization will make pharmaceutical companies more competitive and, above all, future-proof.

In this article:

• Using Augmented Reality to enhance the efficiency of your pharma training
• Proof of concept at a renowned pharmaceutical manufacturer  
• Faster onboarding, fewer errors: the results of the proof of concept

A Bitkom industry association study indicates that around 20 percent of German businesses are currently using AR or VR technologies. Mostly for training and in construction, but rarely in production. Especially pharmaceutical manufacturers are still hesitant, mostly due to concerns about compliance risks. Therefore, we still have limited experience with the true potential. However, in field trials at a pharmaceutical company, employees in production mastered new tasks of greater complexity 44 percent faster with AR support compared to paper-based instructions and accomplished simpler tasks another 15% faster as well. 

In this blog post, we would therefore like to look at the actual AR training processes in production practice. The most important finding up first: AR can also be used under GMP-regulated conditions and can, for example, significantly increase the efficiency of machine operator training on the machine – in the applications described, conducted by Körber, by up to 25 percent.

But first: What is Augmented Reality (AR)?

Augmented Reality (AR) refers to technologies in which images of the real environment on displays are supplemented by computer-generated information (e.g. text, graphics, multimedia). AR merges components from the physical world with digital elements on the display instantly.

In contrast to Virtual Reality (VR), AR users interact with their physical environment and not exclusively with a computer-generated "world" as in computer games. Well-known examples of AR in everyday life are mobile games like Pokémon Go or interactive filters on Snapchat and Instagram. Complex AR applications can be executed using specialized data glasses like the Microsoft HoloLens, eliminating the need for a smartphone or tablet. For example, status data or instructions are displayed in the image of machines, allowing users to have their hands free while interacting with the featured objects. The glasses, in turn, react to head and eye movements, creating a particularly immersive experience. Therefore, AR is also ideally suited for training practical skills.  

A proof of concept conducted by Körber at a renowned European pharmaceutical company shows that Augmented Reality can significantly accelerate practical training processes with suitable learning objectives. The international pharmaceutical company develops new drugs, which requires the production of small batches of up to 45 kilograms. The frequent batch changes are very time-consuming, especially when it comes to setting up and approving the system. For this reason, the consulting experts from the Körber Business Area Pharma were commissioned to develop a proof of concept for digitally controlled workflows. The aim was to ascertain if an AR-supported approach could reduce the total effort and resources required for format changes and line clearance, while still maintaining top quality standards and adhering to GMP regulations. This also required training for employees in order to test the new approach comprehensively.

Setup and execution of the AR training proof of concept

Guided workflows are considered a reliable and comparatively low-barrier introduction to paperless production. In this approach, SOPs that were once on paper are turned into a digital workflow. This allows for the steps to be executed according to the guidance provided, with the use of relevant tools. Körber's Line Optimizer Execute solution was used for this in the proof of concept.

Guided workflows are created using a workflow design tool that's based on UML activity diagrams (Unified Modeling Language). Line Optimizer Execute operates on all internet browsers, making it compatible with tablets as well. For an enhanced experience, it is advisable to use Microsoft's HoloLens 2, as demonstrated in the proof of concept. Körber also provided technical guidance and training for the 22-line operators. The training took place partly on site and partly in remote workshops. In addition, bi-weekly project meetings were held throughout the project using Microsoft Teams.

Results of the AR training proof of concept

The proof of concept provided does not constitute a scientific study, lacking defined dependent variables, an established control group, and matching samples. Thus, the outcomes are primarily qualitative and should be seen as indications of trends rather than rigorous statistical analyses.

Onboarding process: The onboarding process for new specialists involves both position-independent steps like administration, orientation, and security, as well as steps specific to the particular job. Utilizing AR-guided workflows can considerably accelerate the onboarding procedure. Operators were able to learn how to use the workflow guidance after an average of one to two days, which is significantly faster than the 45 days required for training and familiarization without AR support. This would also include troubleshooting steps if these were defined in advance. Acceptance of workflow control was high, with almost all training participants getting to grips with the HoloLens after about a day. Others preferred to work with the tablet.

The results of the proof of concept at a glance: 

New tasks: Employees are tasked with tackling new challenges, typically under the direction of experienced coworkers or by following instructions on paper. However, with AR support, transitions like adapting to a different machine can be achieved approximately 25 percent faster than the typical approach.

Qualification level: With AR-supported training, the trained employees do not primarily learn how to operate a specific machine, but how to use a supporting system. This significantly increases flexibility when deploying employees.

Quality and productivity: Guidance through work processes, automatically controlled and documented by electronic signatures and time-stamped test protocols, avoids errors and increases quality. As a result, GMP compliance has been increased by 25 to 40 percent. The time required to check batch records was reduced by an average of 60 percent. Production efficiency increased by an average of 30 percent.

Overall, the proof of concept showed promising results for the use of AR-supported workflows to improve onboarding processes, increase productivity and enhance quality in the workplace.

Would you like to find out more about the use of augmented reality? Read our detailed white paper with the proof of concept briefly outlined above to increase the efficiency of your pharma training with AR, or get in touch with our internal contact person directly: