Survey: European pharmaceutical manufacturers bet on AI, digital twins and automation to overcome silos and compliance challenges

HOOFDDORP, the Netherlands – A commissioned study conducted by Forrester Consulting on behalf of Hexagon titled, Transforming Pharmaceutical Manufacturing: Overcoming Hurdles With Digital Innovation, sheds light on the priorities and challenges of pharmaceutical manufacturers in Europe.

Forrester surveyed 161 manufacturing technology decision-makers at the manager level and above, responsible for manufacturing processes, quality assurance and testing within pharmaceutical organizations boasting at least $1 billion in annual revenue. The survey was taken between December 2024 and January 2025.

Key findings:

• Cybersecurity, AI and automation lead investments: When asked about their investment priorities in the next 12 months, more than three out of five respondents cited cybersecurity automation (68%), AI for predictive maintenance (65%), physical automation (61%) and AI for native language interfaces (61%).
• Data silos represent a major obstacle: Two-thirds of respondents (68%) reported that data silos hindered informed decision-making in their organization.
• Audits present a major challenge for organizations, with 55% struggling to maintain operational efficiency and 53% finding it challenging to readily demonstrate compliance. Similarly, managing change with auditable traceability is a challenge for 53%.
• OT and IoT cybersecurity is a major concern: 59% of respondents are set to increase spending in IoT for asset tracking and real-time data, while 68% plan on expanding cybersecurity investments. Integrating IoT with cybersecurity automation enhances real-time asset monitoring and management while protecting assets and ensuring operational continuity and compliance.

Digital twins as backbones of smarter factories
With only 17% of respondents reporting they currently use a digital twin of their facilities, the pharmaceutical industry lags behind other sectors. However, when it comes to new projects, four in five firms (79%) are leveraging digital twins to enhance collaboration and precision in designs.

In the future, Adam Cross, Industry Director, Pharmaceuticals & Life Sciences at Hexagon, expects to see digital twins gain rapid adoption as companies seek to break down silos and address compliance challenges.

“The survey shows that the majority of pharmaceutical companies struggle with managing documents and data, ensuring compliance, and managing change. Disjointed systems and silos hinder effective data sharing, making it hard for employees to access the information they need and collaborate,” Cross said.

“However, we're seeing a group of leading companies that are tackling these problems head-on and making significant investments in smart factories, digital twins, automation and artificial intelligence because they see the potential for major gains in efficiency, sustainability and profitability."

Hexagon’s digital twin solution, HxGN SDx®, is used by major pharmaceutical manufacturers such as Bayer, which leverages it for reliable as-built information, faster project delivery and improved data quality.

Contact:
Nicolas Chadeville, Communications and Content Strategy Lead, EMIA
Hexagon’s Asset Lifecycle Intelligence division
Tel: +33 6 80 62 81 47
Email: nicolas.chadeville@hexagon.com