Future of Manufacturing Ireland Q4 2019 by Mediaplanet UK&IE

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Biopharma contributes over €73 billion to Irish exports

MATT MORAN Director, BioPharmaChem Ireland

As global competition for foreign direct investment intensifies, it is vital that the Irish biopharma sector stays at the cutting edge of manufacturing technologies.

he biopharma sector now contributes over €73 billion to the exports of Ireland. It also employs over 30,000 people directly and at least the same amount indirectly. All of the top ten biopharma compa n ies i n t he world have operations in this country.

The i ndu s t r y i nve s t s ab out €1.8 billion annually in process development R&D. Leading way for manufacturing The need for Ireland to sustain its leadersh ip posit ion in manufacturing was prioritised May 2019, by BioPharmaChem Ireland (BPCI) in their fifth strategy s t atement . BP C I i s t he association within Ibec that represents biopharma and chemical manufacturing in Ireland. Companies can prioritise a range of tech n iques and practices that ensure that Irish sites continue to foc us on best practice and retain @BusinessNewsIE

competitive advantage in their manufacturing operations. BPCI is committed to operational excellence and runs a very active specialist group in this field. Biopharma can benefit from AI and VR The industry needs to harness the potential of data – gathering and managing it for outcomebased measurement and personalised healthcare. The sector needs to deal effectively with the amount of data that it generates. Machine learning and artificial intelligence can be deployed to improve the reliabilit y and efficiency of manufacturing. Compan ies are consider ing virtual reality (VR) to support training activities. Such te ch nolog ies wou ld enable companies to train colleagues without risking potential damage to @MediaplanetIE

valuable equipment or jeopardising important product. VR could also be used to simulate and test new manufact ur ing scenarios. In time, one could even look at apply i ng V R to process validation, presenting the opportunity to get products to market more quickly. Robotics in manufacturing Robotics are increasingly deployed in biopharma manufacturing applications. Robots are useful for packing and filling lines in classified or clean areas, or if the product is potentially harmful to hu m a n s . A rob ot c ap able of sanitising clean rooms has been trialled. A robotics skillnet has been established in Ireland, with the primary aim of applying robotic and automation technology within m a nu f ac t u r i n g gener a l ly i n this country. @MediaplanetUK

Cross-industry collaboration to boost innovation Novartis recently announced a collaboration with Microsoft in the area of artificial intelligence. The Novartis AI Innovation L ab w il l str ive to reimag ine medicine, bolstering its capabi l it ies f rom resea rch through commercialisation. BPCI w ill partner w ith Innopharma in r unning best practice workshop in Biopharma 4.0 in Dublin in early December. This meeting will be addressed by one of the founders of Factory 4.0 – Henrik von Scheel. “The collaboration with the Ibec Medtech and Engineering Networks on the Masters in Digitalisation of Manufacturing will enable their employees to identify and grasp new opportunities in the evolving manufacturing sector.”

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Build your company talent pipeline with the Manufacturing Engineering Apprenticeship Combine excellent educational qualifications with workplace learning to ensure work-ready graduates via the new Manufacturing Engineering Apprenticeship. TRISH BREEN Medtech and Polymer Apprenticeships Project Manager, Ibec

pprenticeships can be a g r e at r e c r u it m e nt tool for your company, but many are finding that the programmes offer much more besides. The apprentices are placed straight into practical working environments, so they add business value very quickly and t hey integ rate into t he companies really well. Nationally, the majority of apprentices are achieving, on average, 10%-20% higher results than the corresponding full-time students, and the engagement of students with laboratory and class work is exceptional in comparison to other undergraduates. What a manufacturing engineering apprenticeship offers Manufact ur ing eng ineer ing apprenticeships are suitable for a hugely diverse manufacturing and engineering environment. Developed by the Irish Medtech Association (an Ibec sector) – along with a strong industry consortium and Galway Mayo Institute of Technology as the lead provider – these apprenticeships open doors to medical technology, engineering, polymer, pharma, food, machinery, construction, and ICT sectors. Apprentices have the chance to build aerospace components with the likes of Eire Composites, or contact len ses w it h J& J Vision. Oppor t un it ies ex ist across medtech, agri tech and other sectors. The scheme is a l ready suppor te d by la rge companies such as BD Medical,

DePuy Synthes and Str yker, a nd 41 sma l l-to -med iu m companies (e.g. Cambus Medical, Caragh Precision, Key Plastics), supporting 186 apprentices. How long are the courses? The two-year Technician (Level 6) or three-year Engineer (Level 7) apprenticeships involve 15 weeks a year in Galway Mayo Institute of Technology, Cork Institute of Technology, Limerick Institute of Technology or IT Sligo. The remaining 37 weeks of the year are spent with the employer. Manufacturing and engineering sector Ireland Our ambition is for Ireland to have a n i nter nat iona l reputation for manufacturing and engineering across all key sectors. We believe this can be achieved through sharing best pract ice, developing deeper cross-sectora l col laborat ion a nd cho o si n g p ol ic ie s t h at strengthen our workforce. These apprenticeships are an excellent example of programmes that are helping to support these goals. Next intakes 2020 The nex t Manufacturing Engineering intakes will start in July 2020 with the 15-week academic block starting in all locations in September 2020.

How innovations in technology is shaping the manufacturing industry HEATHER HUMPHREYS TD Minister for Business, Enterprise and Innovation

Advancements to ICT technologies is spurring a radical transformation across the manufacturing sector. Such is the scale of this transformation, that it is often referred to as the fourth industrial revolution, or Industry 4.0.

anufacturing is a cent ra l pi l la r of ou r e conomy, employ i ng over 227,000 people, with 85% of that employment outside of Dublin. Exciting times are ahead as this sector is transforming due to a new wave in technology. Technolog y is advancing across many industry sectors. These include cloud computing; t he Inter net of Th ings; h igh performance computing; advanced aut om ate d a nd aut onomo u s systems and collaborative robotics; artificial intelligence; big data capture and analysis; and digital fabrication (including 3D printing). The adoption of Industry 4.0 in the manufacturing sector and its supply chain will give rise to a wealth of opportunities for both MNCs and SMEs in Ireland. It can play a key role in sustaining competitiveness and employment in key sectors such as pharmaceuticals and chemicals, food and drink, medical devices, computers and electronics, and engineering. However, adopting Industry 4.0 strategies will be a challenge – no matter how big or small your firm. Future Jobs Ireland, our new economic pathway for Ireland, acknowledges these challenges but signals Ireland’s ambition to embrace the opportunities offered. €500m in government funding for digitalization The digital transformation will depend on achieving excellence and critical mass in RD&I that

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underpins Industry 4.0. Here, Ireland is well-placed, having already invested significantly i n a nu mber of cent res of scale including: 1. CONFIR M: an SFI funded Re s e a rch C ent re w it h a focus on the convergence of IT systems and industrial automation systems. 2. I - F o r m : a n S F I f u n d e d Research Centre with a focus on additive manufacturing, c om b i ne d w it h t he u s e of digital technologies in manufacturing. 3. Irish Manufacturing Research (IMR): this Enterprise Ireland (E I)/ I DA I rel a nd f u nde d centre is dedicated to close to market RD&I Industry 4.0 activities, including additive manufacturing/3D printing and with plans to extend ac t iv it y i n col laborat ive robotics and aug mented/ virtual reality. The proposed Advanced Manufacturing Centre (A MC), which IDA Ireland is planning to establish, will complement these centres and respond to the needs of Ireland’s discrete manufacturing industry base. The Government also supports investment in digitalisation through t he D i sr upt ive Te ch nolog ies Innovation Fund with funding of €500m under Project Ireland 2040 and a suite of supports through Enterprise Ireland and IDA Ireland.

Overcoming fears that ‘going digital’ will spell unemployment A key concern is the effect that d i g it a l i s at i o n w i l l h ave o n employment. It is expected to reshape the skills that will be required from the workers of the future. The Government will ensure that the education and training system responds to changing skills needs. For example, the Regional Skills Fora facilitate engagement between enterprise and the education a nd t r a i n i n g p rov ide r s a nd Springboard+ and Skillnet Ireland offer a series of education and training programmes with a focus on the future of work in areas like blockchain, artificial Intelligence, cybersecurity, the Internet of Things, virtual reality and smart factory technologies. These initiatives build on our industrial capabilities built over decades, our thriving community of indigenous supply chain SMEs and the presence of world-leading software and ICT industries. Following extensive engagement with the manufacturing sector, I will shortly launch a new strategy for Industry 4.0 that will ensure that manufacturing in Ireland is at the forefront of the fourth industrial revolution.

Read more at businessnews.ie MEDIAPLANET

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Is Ireland ready for the next wave of biopharmaceutical manufacturing? COLIN CLARKE Science Foundation Ireland Principal Investigator, Systems Biology and Data Analytics Laboratory, NIBRT, Associate Professor, School of Chemical and Biopress Engineering, University College Dublin

Ireland is uniquely positioned to play a significant role in the next generation of biopharmaceutical manufacturing, and continuing to deliver life changing medicines. A revolution in healthcare Biopharmaceuticals (drugs derived from biological sources) have transformed the treatment of chronic diseases such as cancer and inflammatory disorders with more than 350 million patients worldwide benefiting from these me d ic i ne s. The d i s c over y of potential new biopharmaceuticals continues at a staggering pace, encompassing more than 50% of all new medicines in drug discovery pipelines. There are tremendous opportunities to improve human health in the years to come. Making biological medicines T r a d it io n a l c h e m ic a l d r u g s are made t hrough organic or chemical synthesis, combining well defined chemical components to produce a reasonably pure active pharmaceutical ingredient w ith a relatively simple chemical structure. In contrast, biopharmaceuticals utilise living cells to produce a drug substance, which is not only significantly larger, but also several orders of magnitude more structurally complex. Producing safe, uniform products efficiently in a biological system presents a significant challenge for the biopharmaceutical industry. Increasing pressure on the industry Biopharmaceutical companies must invest considerable resources to develop high ly control led, efficient and robust manufacturing processes, that adhere to strict regulatory guidelines. For example, vaccine production can involve in excess of 500 processing steps, 400 raw materials and require MEDIAPLANET

more than 650 individual tests to ensure safety of the final product. The sheer number and diversity as well as increasing sophistication of emerging biopharmaceuticals is putting the industry under considerable pressure. Can we be at the forefront of biopharmaceutical manufacturing? Ireland is uniquely positioned to play a significant role in the next generation of biopharmaceutical manufacturing and continuing to deliver life changing medicines to patients. In Ireland, Biopharma capita l assets now exceed n i ne bi l l ion E u ro s, w it h 4 0 manufacturing plants approved by US FDA which are employing more t han 30,0 0 0 people. Allied to the presence of these companies are Universities and National Institutes, with unique infrastructure training highly skilled employees and perform cutting-edge research through support from Enterprise Ireland and Science Foundation Ireland. Leading the way in Biopharma 4.0 In recent years, biopharmaceutical companies have recognised the impact of data analytics in other manufacturing sectors and are now beg inning to utilise the technology in their manufacturing processes. An additional factor in our ecosystem is the presence of tech and ICT companies that, t h r o u g h c ol l a b o r at io n w it h biotech companies and academics, can support the digitalisation of the industry. For i n s t a nce, t he Nat iona l I n s t it u t e fo r B i o p r o c e s s i n g R e s e a r c h T r a i n i n g (N I B R T )

and Siemens, with support by the IDA, have been working to develop a state-of-the-art data analytics infrastructure to gain new k nowle dge a nd ha r nes s artificial intelligence. The awardwinning initiative, called BioMac, is now supporting biotechnology c omp a n ie s b a s e d i n I rel a nd and abroad to accelerate their digital transformation. Adapting to change T went y ye a rs ago, t he I r i sh government recognised that when patent protection for traditional c he m ic a l me d ic i ne s l ap s e d, t here wou ld be a sig n i fica nt impact on the products being manufactured here. The resulting strateg y to attract biopharma companies to Ireland has been tremendously successful. We are in an enviable position, hav i ng at t rac ted t he biggest wave of new biotech investment anywhere in the world. However – the industry is rapidly changing and we now find ourselves at a critical point in the evolution of drug production – we must not stand still. The la st f ive yea rs have seen the approval of exciting cel l and gene t herapies w it h t ra n sfor mat ive outcomes for patients. Manufacturing these new me d ic i ne s i s ex t remely complex, a nd i n ma ny cases they are radically different from t ho s e c u r r e nt l y m ade he r e . A new co ord i nate d s t rateg ic response, including investment in education and research in new drug manufacture and related technologies, is urgently needed to ensure this next wave of potential i nve s t m e n t i n t o I r e l a n d i s not missed.

INVENTING FOR LIFE At MSD we have and always will be... Inventing for Life. These three powerful words reflect our commitment to inventing new medicines and vaccines that save lives by preventing and fighting disease. MSD Ireland is one of the country’s leading healthcare companies, having first established here over 50 years ago. We currently employ approximately 2,300 employees across five sites in Ballydine, Co Tipperary, Brinny, Co Cork, Carlow and Dublin. We have substantial Human Health and Animal Health businesses, have invested $2.5 billion in our Irish operations and are consistently ranked as one of Ireland’s top 20 companies. A member of Guaranteed Irish, we are proud to be one of Ireland’s leading exporters and our Irish sites manufacture approximately half of MSD’s top twenty products, saving and enhancing lives in over sixty countries around the world.

Learn more about the opportunities available in MSD Ireland at www.msdirelandjobs.com

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Future-fit manufacturing

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MICHEÁL CASSIDY CTO and CO-Founder, Irish Manufacturing Research

The jump to Industry 4.0 can seem intimidating to some. We must make this a smooth, accessible transition for businesses to adopt, and help highlight the benefits of digitisation.

s we move beyond t he initial hype of Industry 4.0, the manufacturing com munit y is star ting to g rapple w it h t he tang ible business opportunities offered by emerging digitalisation and automation technologies. However, the issue is frequently presented in terms of a binary t ra n sfor m at ion f rom to day ’s world to a future digital utopia. The question could instead be articulated as: ‘What is the next step in my journey and is it taking me along the right path?’ It’s not always possible to answer that with 100% certainty, but standing still is not an option. The only constant is change and the pace of that change is accelerating.

Taking a leadership position in sustainability for a low-carbon economy

What does the workforce of the future look like?

New business models are bringing customer-centric solutions to market in a matter of weeks where, previously, this had taken years. Advanced analytics feeding simulation and rapid production technologies mean that Formula One racing teams can build and race a new car every two weeks. Digital supply-chains and 3D printing are enabling customers to order individual-fit sports-shoes at the price point of mass-production. The key for most manufacturers is understanding the benefits of technology investments and defining a business model that makes sense in this environment.

Future generations are looking at employers with a different set of lenses than before. They expect employers to be leaders in diversity, environmental awareness and t o p r ov id e s t i mu l at i n g a n d rewarding work. R e c e nt s u r ve y s o f G e n -Z s entering the workforce highlight a n ex p e c t at ion of c ont i nu a l career development, evolv ing roles and opportunities. Lifelong learning and skills development must be a key part of the future manufacturing environment with intuitive and personalised delivery to generations of digital natives.

The manufacturing industry is ideally placed to steer the global r e s p o n s e fo r s u s t a i n a b i l it y t h rough proac t ive measu res, t h at a re s t ron g ly s upp or te d by new d ig it a l tech nolog ies. These i n novat ion s i nclude IoT-enabled efficient production, on-site renewable generat ion for zero net carbon production, a nd en g a gement i n c i rc u l a r economy ecosystem s t hat minimise the resource intensity of manufacturing supply chains. Technology is changing at an unprecedented rate

Technology needs to support business evolution or, ideally, revolution – it cannot become simply a digital version of business as usual Real-world examples of customer success range from detecting a basic physical quantity and turning this into useful intelligence. For example, detecting unoccupied spaces and turning off lights and AC; through to scheduling complex production environments via AI. Knowledge, awareness and training are significant steps to take in order to demystif y t he tech nolog ies a nd de -r isk future investment.

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Preparing for the challenges of global climate change SIMON MCKEEVER Chief Executive, Irish Exporters Association

Climate change, on a micro and macro level, is our generation’s defining challenge. As an island nation, Ireland is, and will increasingly be, particularly affected by the multifaceted effects of a changing climate over the coming years.

rish businesses, especially those in the food and drink sectors, but also in the logistics a nd t ra n s p or t se c tors, mu s t consider and adapt to measures to manage and mitigate the different effects on their businesses. We welc ome t he m a ny steps already taken by the IEA membersh ip a nd t he Ir ish government at local, regional and national level to reduce their environmental impacts through i nvest ment s i n i n novat ive a nd s u st a i nable solut ion s to ag r ic u lt ura l development, manufactur ing and log istics. However, more can and must be done at all levels to reduce Ireland’s rel i a nc e on fo s s i l f uel s a nd accelerate the transition to a zeroemissions economy. Businesses must be supported through sustainability changes The time for detailed action on tackling climate change is now; albeit, it must be accompanied by a sustainable action plan and supports for businesses. Tightened rules and regulations, designed to limit environmental impacts, are already significantly i n f lu e nc i n g m a nu f ac t u r e r s ’ design and production processes. The European Union’s Circular Economy package for example, which entered into force in July 2018, sets ambitious recycling targets on packaging and packaging waste. With this new legislation,

More can and must be done at all levels to reduce Ireland’s reliance on fossil fuels and accelerate the transition to a zero-emissions economy. the European Commission aims to ‘close the loop’ in product lifecycles through mandating their improved recycling and re-use. Target: Recycling 70% of all EU packaging waste by 2030 With ambitious recycling targets of 70% of all EU packaging waste by 2030, including 80% of ferrous metals, 60% of aluminium, 55% of plastics and 30% of wood, these regulatory changes are already influencing future product design for manufacturing businesses. In addition, ‘Extended Producer Responsibility’ schemes place further governance obligations and compliance costs on goods manufacturers to ensure their environmental sustainability. Manufacturers may move to electric or hybrid HGVs It is not just regulatory compliance costs that we are facing. As a consequence of our geography, and par t ic u lar rel iance on short-sea shipping to the European mainland, Irish exporting and importing businesses will equally be bound to address and prepare for a number of potential transportation challenges. For many exporting and transport

companies, these range from the potential transition to the use of alternative transport fuels such as electric vehicles for last-mile deliver y or hydrogen powered HGVs to the development of fully integrated multimodal transport networks combining air, rail, sea and road cargo movements and digital technologies such as blockchain to streamline the transportation process. Our global climate is changing, both environmentally and in the nature of how and where Irish businesses trade. Besides the political remit to trade, climate change is our generation’s defining challenge and the moment for detailed action is now. While many difficult decisions lie ahead of us in addressing the different challenges arising from effectively preparing and mitigating the impacts of climate change on the Irish exporting community, the Irish Exporters Association will continue to stand ready at a political, technical and business level to assist our members in maximising their businesses opportunities in the face of the climate change. Read more at businessnews.ie MEDIAPLANET

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Global hub supporting growing pharmaceutical industry in and out of Ireland

MAURICE MEADE Managing Director, DHL Global Forwarding, Ireland

As a committed EU member, Ireland is at the heart of Europe and plays a vital role manufacturing and supplying life-saving medicines both globally and in to Europe.

hroughout the past year, there have been a number of Life Sciences start-ups and major expansions in the Irish market. We are home to all 10 of the world’s top 10 pharmaceutical companies, 24 out of 25 of the world’s top biopharma companies and 18 of the world’s top MedTech companies. IDA Ireland has reported that over the past decade, €10bn has been invested into new biopharma and biotech production facilities in the country, representing “close to the biggest wave of investment in new biotech facilities anywhere in the world.”1

Storing and distributing critical drugs safely I rel a nd c a n b o a s t a v ibr a nt industry, manufacturing critical drugs and exporting them globally for decades. But this requires storage, handling and distribution u nder s t r ic t re g u l ator y a nd security conditions and across the full range of temperatures required to protect the drugs. Such critical drugs require high levels of sec ur it y, protect ion from fire and strict temperature-

controlled zones ranging from ‘ambient’ (room temperature), ‘chill’, right through to ‘frozen’ and ‘deep frozen’. An integrated global network “Many companies are beginning to recognise the benefits of a more i nteg rated approach to supply chain management,” says Maurice Meade, MD of DHL Global Fowarding, Ireland. “Traditionally, companies have managed their inbound supply chain at a plant level. But, by enabling a more holistic view of the inbound supply chains, international deliver y networks have reduced complexity, providing visibility from pick up to point of delivery, making them more agile and responsive to ma rket dema nd. Th i s ha s allowed logistics teams to reduce the amount of inventory sitting in warehouses and release working capital for other needs.” Such integration can help the logistics company – and those with whom they collaborate – through the uncertainties that Brexit might give rise to. In one instance, the logistics team in Dublin ensured a successful deliver y of a life

transforming service into the EU ahead of the Brexit deadline. The delivery was a ‘Brexit contingency’ plan, focused on critical patient s upply – a lw ays put t i ng t he patient first. Patients come first in logistics future planning I nve s t m e nt i n d e e p f r o z e n capability is underway to support the complex supply chain needs of the next generation of ground-breaking medicines bei ng resea rched i n Irela nd, personalised medicines and cell and gene therapies that promise to revolutionise disease treatment. Gill McCann, Head of Life Sciences and Healthcare says: “We continue to invest in the solutions needed

GILL MCCANN Head of Life Sciences, DHL Supply Chain, Ireland by our Global Pharmaceutical Customers in Ireland, which are critical to enable patients to access these revolutionary medicines. These treatments are complex in their manufacture, personal to a patient and require a safe pair of hands to safeguard them in transit.” Ireland remains ideally placed to manage global and European ph a r m ac eut ic a l a nd cl i n ic a l supply chains. Supply chain and transportation services help the industry operate compliantly, safely and efficiently, while ensuring the continued provision of lifesustaining and life-transforming medicines to patients worldwide out of the centre of excellence that is the island of Ireland.

About DHL DHL supports the life sciences sector across R&D, pharmaceuticals, medical devices and hospitals, and has developed customised Worldwide Medical Express and Thermonet networks which enable end-to-end proactive monitoring of temperaturesensitive shipments. DHL has its own airline with over 250 dedicated aircraft connecting over 500 airports and 22 major hubs globally. The team has also developed further services for its pharmaceutical customer base - amongst which controlled drugs, deep frozen and GMP services. www.logistics.dhl