Making AI work on the shop floor: What pharma manufacturers need to get right

Dr Rajiv Desai, Senior Technical Advisor – Quality and Regulatory, IPA, highlights what pharma manufacturers need to get right when deploying AI at scale, from data and validation to quality, workforce readiness and human judgement

India’s pharmaceutical industry has built its global reputation on scale, quality, scientific capability and affordability. As the industry enters its next phase of growth, technology will play an increasingly important role in strengthening these foundations. Artificial intelligence (AI), in particular, has the potential to make pharmaceutical manufacturing more predictive, efficient and responsive. Most important “First Time Right”.

But the opportunity is not simply about introducing AI into Pharma manufacturing sites. The real question is how manufacturers can deploy it responsibly, at scale and in a way that strengthens quality and consistency and safe for patients.     

The first step is to focus on the problem, not the technology. Manufacturers should identify where AI can create measurable value addition, whether in predictive maintenance, process optimisation, early warnings on potential failures, visual inspection, Quality monitoring, deviation analysis, failure investigations and root cause analysis. AI should solve a clearly defined manufacturing challenge rather than become another technology pilot.

The second requirement is a strong data foundation. Modern pharmaceutical plants generate vast amounts of information through manufacturing equipment, laboratory instruments, equipment sensors and quality processes. Yet data which is fragmented, inconsistent or difficult to access limits the implementation and value of AI. Manufacturers therefore need reliable, connected and well-governed data, with appropriate controls for integrity, traceability and access.

This becomes particularly important in pharmaceuticals because AI should operate within a highly regulated environment. Quality cannot be an afterthought. AI-enabled systems must be developed with a clear understanding of their intended use, validation requirements, risk management and ongoing performance. As India strengthens its manufacturing quality framework, digital technologies must support, rather than complicate, the industry’s commitment to GMP and regulatory excellence.

There is also a need to keep people at the centre of this transformation. AI should augment human expertise, not replace it. Experienced manufacturing, engineering and quality professionals bring contextual knowledge that cannot always be captured in datasets. AI can help them identify patterns, anticipate risks and analyse information faster, enabling better and more timely decisions.

This makes talent development as important as technology investment. India’s pharmaceutical ecosystem already benefits from strong scientific, engineering and technical capabilities. The next step is to build digital fluency across the manufacturing workforce so that employees understand both the potential and limitations of AI-enabled systems.

The bigger challenge will be moving from isolated pilots to scalable implementation. A successful AI application should be capable of being governed, monitored and responsibly extended across value chain of the pharma manufacturing setup. Recognising that different plants and processes may require different models and controls. This calls for collaboration between manufacturers, technology providers, scientists, engineers and regulators.

This is also where India’s existing manufacturing strengths can become a competitive advantage. The country has spent decades building capabilities in process engineering, quality systems, regulatory compliance and large-scale production. AI can build on this foundation rather than replace it, helping manufacturers turn accumulated operational data into actionable intelligence.

For India, the opportunity is significant. The country has already demonstrated that it can combine scientific capability, manufacturing scale and cost competitiveness to serve the ever increasing needs of the patients globally. AI can help add another dimension to that advantage: manufacturing intelligence.

The future factory should therefore not be defined by how much AI it uses, but by how effectively it combines technology with science, quality and human judgement. If implemented on these foundations, AI can help Indian pharmaceutical manufacturers detect problems earlier, improve consistency, strengthen quality and build more resilient operations.

India’s pharmaceutical journey has always been about capability building. The next chapter can be about using intelligence at scale, while keeping quality, trust and the patient at the centre.

References: 

1.  U.S. Food and Drug Administration (FDA), Artificial Intelligence in Drug Manufacturing / Advanced Manufacturing Framework

2. European Medicines Agency (EMA), Reflection paper on the use of Artificial Intelligence (AI) in the medicinal product lifecycle, 2024

3. International Council for Harmonisation (ICH), ICH Q9(R1): Quality Risk Management.

4. Central Drugs Standard Control Organisation (CDSCO), Revised Schedule M, Government of India.

5. EMA & U.S. FDA, Guiding Principles of Good AI Practice in Drug Development, 2026

6. Government of India, Press Information Bureau, Steps taken to ensure drug quality and curb counterfeit medicines, 2026

AI in pharmaAI in pharmaceutical manufacturingGMP compliancepharma manufacturing technologyPharmaceutical manufacturing
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