Optimize Tech Transfer and Industrialization

Sanofi will use Das­sault Sys­tèmes’ “Made to Cure for Bio­Phar­ma” indus­try solu­tion expe­ri­ence based on the 3DEXPERIENCE plat­form to design, imple­ment, qual­i­fy and oper­ate mod­u­lar pro­duc­tion lines at the two “EVo­lu­tive Facil­i­ties.” These will rely on sin­gle-use tech­nol­o­gy and mobile equip­ment to man­u­fac­ture up to four prod­ucts simul­ta­ne­ous­ly and sus­tain­ably by select­ing the most advanced tech­nolo­gies to reduce their ener­gy con­sump­tion. The plat­form pro­vides a vir­tu­al envi­ron­ment for col­lab­o­ra­tive inno­va­tion and end-to-end data man­age­ment across the life cycle.  Sanofi can expe­ri­ence the man­u­fac­tur­ing sys­tems under devel­op­ment and their oper­a­tion vir­tu­al­ly and opti­mize scale up and indus­tri­al­iza­tion process­es before deploy­ing them. 

“We want to improve people’s lives by giv­ing them faster access to vac­cines and treat­ments while min­i­miz­ing the envi­ron­men­tal impacts of our activ­i­ties,” said Ana Alves, EVo­lu­tive Facil­i­ty Glob­al Project Head & Site Head of Neuville sur Saone, Sanofi. “Das­sault Sys­tèmes deliv­ers the tech­nol­o­gy we need to accel­er­ate the intro­duc­tion of new prod­ucts in the facil­i­ty by sup­port­ing the col­lab­o­ra­tive works of our teams and by strength­en­ing the stan­dard­iza­tion of designs and mod­els. It will also bring capa­bil­i­ties to reach our objec­tive to pro­duce sev­er­al prod­ucts in the EVF in an opti­mized sched­ule, thanks to the dig­i­tal twin.  Then, the 3DEXPERIENCE plat­form will help us to address the com­plex­i­ty of the prod­uct life­cy­cle man­age­ment in a high­ly reg­u­lat­ed envi­ron­ment and for the ben­e­fit of our patients.”

Phar­ma­ceu­ti­cal man­u­fac­tur­ers must qual­i­fy facil­i­ties, equip­ment and process­es before pro­duc­tion to ensure safe­ty and qual­i­ty.  This can take weeks or months depend­ing on the equip­ment con­fig­u­ra­tions and process para­me­ters for dif­fer­ent prod­uct recipes.  Vir­tu­al twins enable man­u­fac­tur­ers to stan­dard­ize mod­ules, reduce this time­frame, and boost their abil­i­ty to quick­ly and mas­sive­ly pro­duce cru­cial therapies. 

With a vir­tu­al twin, Sanofi can visu­al­ize and sim­u­late the recipe, equip­ment and con­sum­ables that a par­tic­u­lar process requires, as well as the flow and activ­i­ty of the mod­ules and oper­a­tors in the “ball­room” – a flex­i­ble and adapt­able area that enables man­u­fac­tur­ers to quick­ly switch between process­es.  Sanofi can add, remove and replace func­tion­al ele­ments and process steps as need­ed in a seam­less way, and recon­fig­ure the pro­duc­tion lines for a fast changeover from one prod­uct to anoth­er one.  It can also accel­er­ate the main activ­i­ties of the life cycle of new mod­ules, process­es and facil­i­ties more quick­ly and cat­a­log them into its prod­uct life cycle man­age­ment for reuse and faster prod­uct changeover.

“The pan­dem­ic made it clear: Bio­Phar­mas must be able to max­i­mize effi­cien­cy and quick­ly pro­vide high-qual­i­ty, inno­v­a­tive ther­a­peu­tics to patients world­wide,” said Claire Biot, Vice Pres­i­dent, Life Sci­ences & Health­care Indus­try, Das­sault Sys­tèmes. “Sanofi is respond­ing to this chal­lenge with next gen­er­a­tion mod­u­lar man­u­fac­tur­ing that can trans­form the speed at which prod­ucts reach patients. Thanks to the 3DEXPERIENCE plat­form, Sanofi will imple­ment new prod­ucts right the first time, with faster pro­duc­tion ramp-ups and con­cur­rent process pro­duc­tion for built-in flex­i­bil­i­ty. Ergonom­ics on the shop floor can be sim­u­lat­ed and improved.”