Leveraging a CEM when planning for manufacturing resiliency


Manufacturing leaders need to visualize the evolving scenarios of threats to their operations. A business continuity plan designed with scalable and agile critical event management technology supports their vision to mitigate vulnerabilities and nurture growth.

Key Takeaways: 

  • Harnessing real-time data and using it to build a common operating picture improves situational awareness and provides contextual validity. 
  • Leaders can detect and understand the threat nature using visual risk intelligence that helps mitigate risks. 
  • Critical communication technology improves coordination and speeds up recovery efforts while normalizing operations with minimal impacts. 

When looking to build a strong business continuity structure, the most common scenarios manufacturing leaders keep in mind are the impacts of critical events on manufacturing operations and productions.

Manufacturing industries that have dispersed operational plants are having a greater level of challenges. In a plant located at a far-flung location, cyclones may keep the operations shut, while other dispersed branches continue their operations- but with the lagging support from a disrupted plant, supply chain operations collapse and hit customer fulfillment.

Simultaneously, fire means the closure of a manufacturing plant that needs repairs or relocations. More such growing critical event challenges emerge daily. The types of threat may be different by location, with different types of rescue efforts being brought forward for earthquakes in one place and hailstorms in another place.

Visual risk intelligence and location intelligence improves decision-making and builds a better design that encourages business continuity while giving the best ability to mitigate the impacts of critical events at a large scale.

Why do manufacturing leaders focus on business continuity?manufacturing leaders focus on business continuity - zapoj

It is important organizations of all types should consider business continuity or resilience for operational processes. Identifying or addressing resiliency between every step of the process is crucial in manufacturing industries too.

From securing an IT infrastructure to preventing disruptions to critical equipment and facilities through to providing employee safety and maintaining a healthy supply chain management, they can reduce vulnerabilities to operational efficiency.

If leaders fail to realize the importance of business continuity, they are unable to withstand a variety of threats during critical events, which not only impacts their reliability but also affects their growth.

As per IDC, businesses can have monetary losses of up to $100,000 per hour for an infrastructure failure. Critical application failure costs businesses up to $ 1 million per hour.

Each part of the manufacturing process is integral to each other- which means the failure of each component has a ripple effect on the resiliency and most importantly growth. Rapidly responding to critical events and adapting to their impacts can help manufacturing leaders become resilient.

Zapoj CEM can provide flexible business continuity strategies that manufacturing leaders can utilize to be prepared for unexpected threats and get the ability to detect, respond, and recover from critical event threats.

Achieve a better view into threat recoveryAchieve a better view into threat recovery - zapoj

Organizations today look to continue their operations across every significant area. Disaster recovery can only be one side of the resiliency approach, but business continuity provides a holistic advantage to leaders and their future growth scope.

To achieve speed to overall resiliency strategy, recovery efforts should be designed ahead of time – not only when disaster emerges with the trigger of a fire, storm, flood, or other devastative incidents.

The ability to harness historical threat data in respect to the impacts that ensued some time back or a year ago could lead to the discovery of the exact causes of IT system failures or critical equipment failures in some parts of the manufacturing plants. In addition, artificial intelligence that simplifies the identification of threat patterns can reveal missing links in the recovery efforts of a particular time and suggest improved methods to remediate vulnerabilities to operational efficiency.

Zapoj gathers lots of data- from imagery satellite, social media channels, weather feeds, public or private agencies, and multiple sources that interact about the events. This robust CEM platform is a dedicated architecture to preserve data into its database, which gives manufacturing leaders an efficient way to analyze and observe – where the impact was so harsher, how long was the facility disruption, or did their emergency response team manage the threat to their assets with their best capability.

By understanding the conditions and impacts of the critical events, leaders can make an informed decision about how much resources they need to mitigate the threat of facility disruptions or what changes they must make to their contingency plan in response to the identical threat in the future.

With an ability to combine a variety of datasets, Zapoj can perform advanced calculations that help reveal ways to ensure employee safety in various situations during a fire, man-made disaster, or extreme weather conditions.

Respond to threats to manufacturing operational processes Respond to threats to manufacturing operational processes

Critical events are becoming more stubborn, frequent, and less predictable. Like every business sector, manufacturing needs to safeguard its people and assets so that the impact of operation disruptions does not linger for indefinite periods.

The winter weather calamities, cyclones or storms and man-made disasters raise challenges to operational continuity. The most common scenario of the impacts of these critical events is facility disruptions due to roof collapses, failed IT systems, or power outages.

To respond to business closures because of the facility disruptions, critical event management-reinforced recovery efforts are the most desirable. The emergency preparedness plan works efficiently and effectively for emergency response teams in different dispersed manufacturing plants before, during, and after the critical events.

Leaders also need to gather real-time data to ensure safety and resilience to their supply chain efficiency. By building a common operating picture, it is easier to achieve situational awareness about where it is facing weather challenges or political unrest. The location data also helps track evolving situations ahead of its route and allows emergency response teams to coordinate better. As a result, the collaborative approach helps optimize resources and manpower efficiently and facilitates operational continuity.

As discussed earlier, using historical data in the Zapoj database, leaders can prioritize incidents that are more likely to occur and impact business operations.  Different types of testing drills can be effective and help manage rescue efforts for them.

It is important to communicate as quickly as possible to collaborate with the right person and facilitate the recovery efforts. Using a mass notification system in Zapoj, they create customized message templates specific to the evolving situations and build contextual awareness for the receivers.

During any critical situation, if employees are in harm’s way, location intelligence gives location accuracy, and reaching out to the right person becomes easier with an up-to-date contact center built upon Zapoj. Emergency responders can escalate messages to the right person to the right location without creating any panic or adding to information fatigue. In safeguarding employees, real-time critical communication plays an important role. The multimodal communication channel keeps everyone informed and protected.

Business continuity in the manufacturing sector is critical to reducing the supply shortage, meeting consumer demand while building strategies to prevent vulnerabilities.

Zapoj harnesses bespoke AI technologies to equip its capabilities to build visual risk intelligence and situational awareness. With the ability to collect data from a global network of tools and technologies and across the manufacturing locations, leaders utilize Zapoj to monitor every step of the manufacturing processes. The real-time visibility into end-to-end operations involving workforce, IT systems, logistics, or supply chain movement provides actionable insights and accuracy into decision-making.

As leaders need to coordinate and collaborate, real-time critical communications improve understanding and therefore keep their emergency people up for mitigating risks and keep their employees protected.

A major part of a business continuity plan depends on the efficiency and effectiveness of tools and techniques that leaders use to handle risks and restore operations.  Zapoj is purpose-built to meet the expectations of emergency response teams to ensure manufacturing resilience.

We know manufacturing resilience is important to future growth and customer satisfaction. Being a manufacturing leader if you are determined to prevent disruptions and support business continuity, leverage Zapoj. Schedule a demo today.


Top Three Steps to Keeping Your Pharma Manufacturing Employees Safe

Seeking to build safety monitoring into employee’s regular work routine, the pharma industry needs to employ a technology that integrates location intelligence to map fieldworkers, lone workers, or on-premise staff in the manufacturing site in real-time. When facing health hazards or other safety threats, an automated emergency notification system with two-way communication technology improves staff outreach and ensures safety with a focus on a robust recovery process. A critical event management platform like Zapoj provides modern AI technology to handle pharma manufacturing risks to ensure employee health and safety.

Facilitating situational awareness and emergency response 

Facilitating situational awareness and emergency response - zapoj vectors

Pharma manufacturing plants including warehouse, distribution, and laboratory facilities have regular dealings with heavy machinery and equipment. During the manufacturing and production of drugs or other pharmaceutical products, chemical handling is a daily routine for workers. Pharma leaders must be mindful of manufacturing safety compliance and regulatory standards. Some critical fields for observation and maintenance involve laboratory safety precautions, chemical handling, risk assessment, and material safety assurance- emerging as the tough piece of workplace health safety management to handle.

Zapoj can enable leaders to use AI-driven critical event management technology to significantly drives the safety and health goals of their employees. Crisis communication provides effectiveness to comply with the worker health and safety guidelines.

Situational awareness increases visibility into every touchpoint by closely interacting with data. A real-time threat feed is an active source of information to know what’s happening around its plants and to its people. Chemical manufacturing can deploy situational awareness to monitor if there’s any chemical spill or safety risk from heavy machinery. Using an emergency alerting system, they can notify their employees of the risk and warn them of the evolving situations. As employees are dispersed widely across many of the manufacturing plants, employee outreach must be flexible and outright without having to worry about inefficiency in notification delivery. Location intelligence simplifies the process of identifying the right people in harm’s way and providing resources to accelerate the risk mitigation or evacuation process.

In addition, pharma needs to continually gather different layers of data points to assess risk. Zapoj CEM brings the flexibility of assessing historical data in line with a new set of data to define improvements and strengthen future threat capability.

A chemical spill is a usual incident in the manufacturing or laboratory settings, but it requires immediate attention to prevent its hazardous effects on employee health and safety. Exposure to biohazards, radioactive or inflammable compounds can choke and cause health injury. An automated notification reaches the responder to enable an immediate action to reduce its exposure or impact. Manufacturing leaders can therefore optimize situational awareness capability and location intelligence to detect the source of a chemical spill in real-time and automate a notification that prioritizes spill cleanup processes, helping build a safe workplace for employees.

Employee health screening and disease prevention Employee health screening and disease prevention - zapoj Critical Event Management vectors

Having ample resources to reduce the COVID-19 infectious disease outbreak or exposure has become mandatory for every industry, and pharma manufacturing is seeing this as a step to ensuring public health safety.

As is with the higher frequency proneness of the COVID-19 transmission, pharma can use visual risk intelligence to implement health screening for their employees or people working at different facilities. The opt-in health survey capability allows the staff to share health status or self-report symptoms or contact, and infection-related information with the emergency response team to proactively facilitate the isolation process and restrict transmission in the premises. The built-in contact base also keeps records of the staff with symptoms or temperature to track the health status and initiate a timely return to the workplace as per health guidelines.

Facility mapping scales at speed as the visual risk intelligence and location intelligence capabilities provide accuracy in mapping locations or spaces with a higher probability of infection tendency. So, real-time tracking and monitoring keep everyone informed of infection contact to immediately suggest sanitization of the particular location or site. The solution helps pharma understand the infection risk, evaluate its strategy to curb infection, and develop a safe and risk-free environment for a return to work and continue to achieve operational efficiency.

Real-time emergency notifications 

Real-time emergency notifications- zapoj Critical Event Management

With the ability to use real-time mass notifications on multi-modal channels, the emergency response team can achieve their mission to implement occupational work and health safety and security for their employees from the potential health risk from heavy machinery or factory equipment and exposure to threats like critical weather, fire, active shootout, or terrorism.

As location intelligence identifies people in danger, real-time mass notifications scale to support thousands of people with resources that can provide consistent messaging assistance and take them out of risk without confusing or panicking the others in the community. Real-time messaging, reminder capabilities with two-way messaging are robust to get across the right message until it is acknowledged. This enhanced capability helps pharma monitor and conduct safety operations for lone workers and many people working at the manufacturing site.

Zapoj Critical Event Management platform is built to give pharma manufacturing real-time threat mitigation capability.  By reducing the impact before critical events emerge to be affecting their operations for an indefinite period, pharma provides adequate resources and assistance to its people to keep them informed, safe and secure. As workforce or employee safety enables businesses to run efficiently and smoothly, Zapoj empowers pharma manufacturers to protect their people during any point of emergency, providing long-term sustainability and cost-effectiveness that improves ROI.

If you want to know more about Zapoj CEM or deploy it into your products, schedule a call to initiate a demo.


How Leaders Can Drive Operational Efficiency and Performance in Pharma Industry?


In pharma manufacturing, leaders need critical event management solutions to improve risk management in response to critical threats and prioritize business continuity.

Key Takeaways

  • By leveraging situational awareness through Zapoj CEM, leaders can decide corrective actions to drive sustainable performance for supply chain operations. 
  • Location intelligence combined with greater collaboration capabilities improves employee safety and facility management that ensure facility effectiveness and employee productivity.
  • Visual risk intelligence helps build a single pane of glass to drive asset performance and take care of IT system health. 

From drug production and packaging to supply chain distribution – pharma manufacturing has sought to adopt a more secure approach to making their operation efficient and resilient. The adaptability to the increasing vulnerabilities needs them to make an investment into robust AI-based digital transformation that encourages pharma innovation and modernization. As a result, with enhanced product design and manufacturing process and control, pharma can ensure the availability of products throughout the manufacturing lifecycle.

But, the uninterrupted performance of the pharma manufacturing life cycle does not involve just a single unit to deliver outstanding and robust performance capabilities. The dependency on each core part for achieving operational efficiency is significant to the success and growth of pharma. With a firm grasp of AI-powered critical event management tools, pharma executives can build digitally-transformed drug manufacturing operations, which can facilitate the mitigation of perilous risks.

However, pharma continues to increasingly become vulnerable to disruption. Smart pharma manufacturing is finding ways to tap critical event management capabilities as found in tools like Zapoj to combine the power of artificial intelligence. This way, leaders can gain predictability into threats with a high level of accuracy and risk mitigation capabilities at scale.

Leverage predictive insights to meet market demands

Leverage predictive insights to meet market demands - zapoj vectors

The collaborative effort of supplier and distributor in achieving operational excellence is key to fulfilling market demand. The global market pressure subsides with the supply reaching the destinations. Location intelligence provides real-time actionable insights into every disparate location where goods are manufactured- from the raw material sites to the plants, from where logistics begins its customer journey.

By developing a holistic view into the global network of supply chains, Zapoj CEM brings real-time threat feeds that help improve decisions, investigate threats, and get prepared for preventing supply chain risk – making the supply chain operations more efficient and future-proof.

Delve deep to see the bigger picture of machine or IT health Delve deep to see the bigger picture of machine or IT health - zapoj CEM

Usually, pharma being an asset-intensive industry, a dozen of automated production lines and pieces of machinery is sitting across different plants, which must adhere to operational efficiency each passing hour. A real-time alert notification with location intelligence from the IoT devices delivers vital efficiencies.

Which machines are idle, which plants need immediate maintenance for their lines of machinery are some of the critical observations to address instantly to mitigate equipment failure and continue operations.  The derivation of location intelligence provides an accurate time frame. Pharma executives can use this information to build real-time visual risk intelligence to allocate resources for emergency responders and help with risk management efforts.

Similar to the operational efficiency of critical equipment, each critical process of manufacturing production and distribution also relies on efficient IT systems. That might mean maintaining the performance of a range of IT tools including ERP, CRM, HRSM, or Asset Management systems to allow a huge line of crucial operations.

Building close monitoring into these systems using a common operating picture helps pharma executives predict how IT system disruption is going to affect the entire line of operations.

A visual risk intelligence-driven notification from Zapoj can alert of the malfunctioning of ERP systems as they hinder process control and lose track of a specific lot of drugs or medical devices or inventory. Furthermore, any vulnerabilities from extreme heat or flood, or man-made threats to pharma IT assets – CRM, HRSM, or Asset Management turn passive with smart digital workflows that escalate to alert emergency IT response teams for a proactive mitigation approach.

Building contextual awareness for safe and secure operationsBuilding contextual awareness for safe and secure operations - zapoj work

Creating and implementing plans to keep pharma sites safe or prevent facility disruptions is important as they provide a comprehensive solution to manage each of the sites’ operations while also motivating people to work without having to worry about exposure to chemical hazards or other safety risks. If facilities are open to work, or susceptible to unpredictable critical threats – all related information is handy from Zapoj CEM, allowing pharma leaders to keep their employees informed and safe from possible threats- and turn pharma facilities into safer places to work.

Having geo-fencing-based location analytics makes tracing the right person in danger impactful and gives contextual awareness capabilities. This provides efficacy in reducing the response time to vulnerability with data-backed improved decision making.

During critical events like fire, extreme weather conditions like cyclones or floods, industry hazards like chemical spills, or an active shootout – pharma can build situational awareness into the evolving situations and take a more robust approach to employee safety and security. The built-in emergency communications or mass notifications efficiently facilitate team collaboration and response through conference bridging capabilities. Pharma facility executives therefore can operationalize emergency efforts and determine the next step of mitigation.

In the context of building best practices into operational efficiency, leaders have long embraced sophisticated technologies. However, with the growing frequency of critical events and their evolving nature, industrial businesses have realized the need for technologies that help unify data from various disparate systems and provide a holistic view into the efficient ways to manage and drive operational efficiency in real-time.  To help increase efficiency in pharma manufacturing, Zapoj CEM offers a unique approach to optimizing asset performance, supply chain operations, employee safety and security, IT system robustness, and facility management through AI-based advanced situational awareness and location intelligence.

With real-time threat mitigation support for the manufacturing ecosystem like pharma, Zapoj delivers the best value to business leaders and ensures profitable ROI by eliminating waste.

For queries on deployment in your premises, give us a call to schedule a demo.