Online learning proves crucial in pharma manufacturing

COVID-19 has left its mark on training structures within the pharmaceutical industry. With dispersed workforces, no access to one-on-one training and remote or distanced working the norm, essential and critical workplace learning has taken a hit. Alex Bunting, I Holland marketing manager, explores the benefits online learning brings to the industry.

The solid dose manufacturing sector has had to rethink traditional learning methods and change course to digitisation to keep employees informed and educated in processes and regulatory requirements.

Investment in e-learning is helping companies to sail the stormy seas of the pandemic. Improving manufacturing skills within a company is critical to its success and key to continuous quality improvement. Specially designed online training is providing vital professional development to ensure skills and knowledge are still on track and being utilised on the production floor.

Online learning helps meet tablet demand

Thanks to its cost-effectiveness, ease of transportation, chemical stability and patient familiarity, the demand for solid oral dose continues to grow.

As the competition increases to manufacture mass-produced tablets, companies need to ensure staff understand the processes required to produce high quantities of quality tablets, both quickly and efficiently. Online learning is an effective solution.

For optimised manufacturing processes, the importance of skilled and well-trained operators, technicians, supervisors and managers is essential. Investing in learning and development provides several tangible benefits including reduced downtime, greater productivity and higher profits. Effective training will not only save on time and labour by recognising problems that could stop production before they happen, but also result in an informed and driven workforce.

Manufacturers should consider the technical expertise and skills gaps found within the workforce, as this can hugely impact on the bottom line. The introduction of technology-enabled learning is helping companies improve the capability of their staff and the sector is seeing huge growth in recent years, having increased by 900% since the year 2000. Its popularity is set to continue, particularly in the wake of the pandemic.

Getting out of a sticky situation

Due to the difficult nature of pharmaceutical formulations and complications involved in the successful compression of solid dose forms, production can be challenging. It requires an understanding of all processes involved, from implementing the correct tablet design to knowing what tablet tool steel material and coating should be used to enhance the process. There should also be knowledge of how to quickly solve problems. Take sticking as an example - one of the most common problems during solid dose manufacturing.

Sticking occurs when particles of the tablet formulation adhere to the punch face. It has a negative effect on the appearance of the tablet and can become so serious that production is interrupted. In extreme cases, the punches may have to be removed to be cleaned. This is disruptive, labour intensive, reduces the quantity produced and increases costs. It is therefore critical to understand how to resolve the issue quickly. If the operator is not familiar with the problem and how to resolve it, production will be severely affected. This makes training crucial to efficient tablet production.

Why e-learning is beneficial

E-learning is becoming a more practical option for productivity improvement, particularly to train people in new skill sets and updating knowledge. Although training may take place ‘on the job’, finding the time and the correct information can prove to be difficult. Work distancing rules must also now be factored in, making face-to-face learning problematic.

This has been addressed by many in the industry, including tablet tooling manufacturers. Learning programmes have been designed to combine comprehensive and flexible courses in a wide variety of disciplines. These have been specifically created to conveniently take place in the workplace or a home office.

Before investing in e-learning, it is important to check whether the programme is adaptable and includes all the learning resources, skill sets and levels required for everyone from a press operator to a plant manager. Also ensure that it includes the following key benefits for long-term learning:

• Engagement – Modules should be short and clear, with engaging content. As tablet production includes many elements, training should be delivered in the form of infographics, videos and quizzes to enhance the learning experience. Modules that can be picked up and put down with ease will also help with engagement. If users are working from home, this style of training is important for continuation.

• Flexibility – A substantial benefit of online learning is its flexibility to support those in manufacturing who are looking to further understand tabletting - whether presses, compression tooling or the management of the entire process. E-learning can be integrated with in-house training packages and work alongside or boost skills learnt on the shop floor. Online training can also work around production schedules and does not take away from productivity. These platforms allow employees the flexibility to revisit key information when they need it.

• Productivity enhancement – Innovative equipment like the latest tablet press or enhanced tooling will go a long way in efficient production. It is important to remember that proficient training will also enhance overall equipment effectiveness. If staff are skilled and understand how to run the production line competently and problem-solve confidently, then tablet manufacturing processes will be optimised.

• Economical – Tablet manufacturers must produce tablets in the most cost-effective way, and this principle should also be applied when it comes to training staff. E-learning provides an economical training solution that results in better performance and faster production. Saving time can save costs. For example, if training is required in tooling maintenance, trainees may have to wait several months to receive face-to-face or seminar training from an expert. E-learning can reduce employees’ learning time by as much as 60% when compared to traditional learning.

• Long-term learning – A huge benefit of online platforms is the ease and speed with which they can be revised. New regulations, requirements and operating procedures are introduced within the pharmaceutical industry regularly, therefore any e-learning technology or resource should have the ability to incorporate these new updates and the latest industry guidelines.

• Multi-disciplined – It is important that the platform has the option to incorporate a wide variety of subjects, allowing staff to broaden their skill set. For example, when looking to improve their knowledge on tablet compression tooling, look for modules that cover everything from the basic subjects like an ‘introduction to tablet tooling and terminology’ and ‘tooling maintenance’, to more advanced levels like ‘troubleshooting production problems’. This allows employees of all ability levels to access the learning package and improve their expertise.

• Staff progression – E-learning can accommodate everyone from director-level to operators looking to improve their knowledge. Some platforms include newly developed courses designed with a hierarchical system, giving training managers and supervisors the ability to do a full audit by tracking and reporting employee development and certification. With a classified structure, courses can be used for comparison purposes across different departments, job roles, sites and countries.

Online training improves tablet production

To meet market demands, quality tablets have to be produced quickly and cost-effectively. This requires optimised tablet production. Reliance on equipment would be an oversight, as staff play a key role in efficient and effective manufacture. It is therefore essential that training takes place.

It would be a mistake to allow the upskilling of staff to slip, even in the current climate during the pandemic. Proficient and well-planned e-learning is an important element in efficient production processes. If a company has educated, well-trained and knowledgeable employees, it will have a direct impact on productivity. •

TABLET MANUFACTURE E-LEARNING PROGRAMMES

I Holland has launched an online learning platform that takes advantage of the materials developed in over 75 years of experience. The programme focuses on tablet compression tooling and offers professionals comprehensive and flexible courses in a wide variety of disciplines. The courses are designed for everyone from director-level to engineers and operators who are looking to improve their knowledge and they can be customised to individual company requirements. Visit tablettingscience.com/online-training to find out more about these e-learning programmes.

I Holland – www.iholland.co.uk