A significant cost factor in pharmaceutical production is incorrect operation, often caused by a lack of training or well-intentioned but incorrect actions when troubleshooting. Fette Compacting tackles these problems at their root – with the help of new digital tools. An initial training program in virtual reality is already ready for use: the preparation of an isolator for cleaning with avatar “Helmut”.

“A machine is only as good as the people operating it,” stresses Britta von Selchow, Head of Digital Product Innovation at Fette Compacting. Around half of all errors in pharmaceutical production occur due to inadequately trained personnel. The resulting costs for companies reach up to the high six-figure range every year. Training sessions are therefore essential for efficient and reliable production.

Fette Compacting’s newly developed digital instruments specifically target operator know-how. This starts with a virtual reality training offer: employees can practice the cleaning and tooling processes in production under containment conditions based on the example of a virtual isolator. “Customers can repeat the training as often as necessary without risk and other limitations,” explains von Selchow, “until all hand movements are learned and the process flows are internalized. During this period, the capacity of the actual machine remains available for production. The VR application even permits training sessions before a machine is installed.”

Learning with high scores and an avatar
The virtual training process requires the use of a gaming notebook, VR goggles, and two controllers. The employee slips into the virtual glove ports and learns the cleaning process based on an interactive checklist. The brain perceives these actions as real. To increase the level of immersion even further, the developers even recorded the actual sounds for every activity and integrated these into the pro- gram. For instance, the operator hears the typical clicking when they close the glove port in virtual reality. A high score provides additional learning motivation: the highest scores are obtained by employees who remove a particularly high number of product residues at critical points in the isolator. The test mode is another highlight, where employees can complete a test in the virtual world. Those who master certain tasks receive a certificate.

But employees are not just guided through the process by checklists and illuminated objects. “Helmut” is also there to help with the initial training. The avatar is based on a real person called Helmut Bommrowitz, Manager Technology Center and long-term Fette Compacting employee. “In my so far 47 years at Fette Compacting I have answered countless questions on the tablet presses,” reminisces Bommrowitz with a grin. “So my colleague Britta von Selchow asked me if I would like to be available virtually as an avatar.”

Digital outlook: troubleshooting with a guide and augmented reality
In addition to the VR training, Fette Compacting is working on other digital applications that are primarily intended to provide valuable assistance with troubleshooting. For example, this includes a digital step-by-step guide that provides troubleshooting instructions based on the error messages issued by the tablet press. In the event that even this instructed troubleshooting is not successful, in future, users will be able to count on real-time remote support with an augmented reality function. In the next issues of What’s Next? we will report on this and other digital solutions from Fette Compacting.

Please do not hesitate to contact us if you have any queries.

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