The life sciences industry operates under immense pressure to maintain product quality, meet strict regulatory standards and optimize efficiency. At the same time, many manufacturers struggle with outdated systems and processes that exacerbate bottlenecks, slow down production and increase the risk of noncompliance. Heading into 2025, only 31%¹ of life sciences compliance and risk leaders feel “very prepared” to meet compliance and risk challenges and over half (56%) expect to face more resource constraints.

As the stakes grow higher, wearable devices and biometric technology offer a promising way to ease these burdens. From streamlining batch releases to automating compliance checks, these technologies can help life sciences manufacturers find breathing room in their processes without compromising quality or safety. 

This article dives into how wearables and biometrics address some of the most pressing challenges in the industry and what manufacturers need to know to implement them effectively.

Compliance: Let Technology Do the Heavy Lifting

Regulatory compliance is the backbone of life sciences manufacturing, but it’s also a major time commitment. Every step of the process needs to be documented, verified and audit ready. Traditionally, this has meant a lot of paperwork, passwords and manual checks. It’s tedious, and worse, it’s prone to errors. Wearables and biometric technologies offer a way to automate and simplify compliance while maintaining the high standards regulators demand.

Secure and auditable biometric access control

Biometrics like fingerprint or facial recognition offer a more secure and reliable method for granting access to sensitive workflows and systems. Unlike passwords or swipe cards, which can be shared or stolen, biometric credentials are unique to everyone, making them harder to compromise. Take, for example, a production supervisor who needs to approve a manufacturing batch. Instead of logging into multiple systems or locating physical keys, the supervisor could verify their identity with a quick fingerprint scan.

These technologies also generate detailed, auditable logs that track who accessed specific areas or systems and when. This is particularly useful during inspections or audits, as manufacturers can quickly demonstrate adherence to access control protocols without poring over manual records.

Real-time protocol adherence via wearables

Wearables like smart badges or wristbands equipped with proximity sensors and motion trackers can monitor whether employees are adhering to critical protocols. For instance, a wearable could verify if employees sanitize their hands upon entering a sterile environment, immediately alerting them (or their supervisors) if a step is missed. The wearable’s logs create a verifiable trail for audits, reducing reliance on manual checks.

By cutting out tedious manual processes and reducing human error, wearables and biometrics make it easier—and faster—for manufacturers to stay compliant and secure.

Operational Efficiency: Cut Down the Bottlenecks

Efficiency is critical in life sciences manufacturing, where delays can impact supply chains and, ultimately, patient outcomes. Yet bottlenecks—such as waiting for batch release approvals or tracking down missing documentation—persist. Wearables and biometrics help manufacturers eliminate these obstacles, shaving time off critical processes without compromising quality or safety.

Streamlined batch releases

The batch release process in life sciences manufacturing is notoriously intricate, often involving multiple layers of data review, approval workflows and compliance checks. While critical for ensuring safety and efficacy, these steps can create bottlenecks, delaying production timelines.

Biometric authentication streamlines batch approvals by providing secure, instant access to critical workflows. Instead of requiring physical signatures or password-based logins for every checkpoint, supervisors can verify their identity with a fingerprint scan or facial recognition. This simple yet powerful change can shave hours or even days off the process by reducing the friction associated with manual approvals.

Automated documentation

Wearables equipped with barcode scanners or RFID readers can automatically capture data related to equipment usage, material handling or employee activities. For instance, when a technician uses a sterilizer, a wearable device would automatically record the action, timestamp it and upload the data to a centralized system. This ensures real-time accuracy, reducing the risk of manual entry errors that can lead to costly investigations or recalls.

These technologies enable manufacturers to optimize workflows, minimize delays and achieve greater throughput without compromising quality or compliance.

Productivity: Help Employees Do Their Best Work

Employee productivity often suffers under traditional systems that require repetitive, time-consuming access protocols. Wearables and biometrics address this challenge by streamlining interactions with secure systems, ultimately improving user experience without compromising security.

Eliminating friction in daily operations

Traditional access protocols—such as manual logbooks or password-based systems—can be cumbersome and error-prone. Biometric authentication simplifies these processes, allowing employees to log in or access restricted areas with a single scan or gesture. Wearables add another layer of convenience by enabling hands-free operations, particularly useful in environments where cleanliness or safety is paramount.

Real-time guidance through wearables

Wearables like smart glasses can provide on-the-job support, displaying context-specific instructions directly in an employee’s field of vision. Imagine a technician calibrating a complex machine. Instead of consulting lengthy manuals, they could follow step-by-step visual instructions delivered via smart glasses, reducing errors and training time.

By reducing the cognitive and physical burdens associated with traditional access and documentation protocols, wearables and biometrics create a more seamless and user-friendly work environment. This not only boosts productivity but also improves job satisfaction, helping manufacturers retain skilled workers in a competitive labor market.

Making It Work: Practical Advice for Adoption

Of course, adopting new technology isn’t as simple as flipping a switch. It takes planning, buy-in and a solid understanding of how to integrate these tools into your existing operations. Here are some key considerations for manufacturers looking to adopt wearables and biometrics:

• Address Organizational Change. Introducing new technologies often requires a cultural shift. Manufacturers should engage employees early in the process, providing training and clear communication about how these tools will benefit both the company and its workforce. Resistance to change can be mitigated by demonstrating how the technologies will make employees’ jobs easier and more efficient. 

For example, in a cleanroom environment, employees may initially feel wary about wearable devices monitoring their movements. Clear communication can alleviate these concerns by explaining that the technology isn’t about tracking individuals but ensuring safety protocols are followed consistently. Training sessions should focus on building confidence with the tools, showing how wearables can reduce manual tasks like logging every handwashing event, allowing employees to focus on higher-value responsibilities.

Including employees in early conversations about the rollout also helps to identify potential hurdles and foster a sense of ownership. Managers can solicit feedback on pilot programs, addressing concerns and incorporating practical suggestions into the broader implementation strategy.

• Ensure Seamless System Integration. Wearables and biometrics should integrate seamlessly with existing manufacturing systems, such as enterprise resource planning (ERP) or manufacturing execution systems (MES). Compatibility is crucial for ensuring that data flows smoothly between systems, enabling a unified and efficient workflow. Without this level of integration, manufacturers risk creating data silos that require additional manual reconciliation, negating the efficiency gains the technology promises. 

Another consideration is future scalability. Manufacturers should evaluate whether the technology can support expansions, such as new production lines or facilities, without requiring significant infrastructure changes. Scalable systems allow organizations to reap long-term benefits as operations grow and evolve.

• Align with Compliance Frameworks. Any new technology must align with existing regulatory requirements and compliance frameworks. Manufacturers should involve compliance teams during the planning phase to ensure that wearables and biometrics meet industry standards. Additionally, organizations should conduct regular audits and assessments to verify that the technologies remain effective and compliant over time. A strong governance policy should outline how data is collected, stored and accessed, with encryption protocols in place to secure sensitive information.

Incorporating regular system validations is also essential. This might include quarterly tests of biometric scanners to verify accuracy or simulated audits to evaluate whether wearable data logs meet documentation requirements for regulators.

• Pilot and Iterate. Rolling out wearables and biometrics across an entire operation all at once can be overwhelming and risky. Instead, manufacturers should start small by running pilot programs in specific departments or facilities.

For instance, a biologics manufacturer might first deploy biometric access controls in its cleanroom environments, monitoring how well the technology integrates with existing workflows and identifying any challenges employees face. By measuring the impact of this pilot—such as reductions in manual access log errors or faster approval times—manufacturers can gather valuable insights to refine the rollout before expanding the technology to other areas.

Reshaping Life Sciences Through Wearables and Biometrics

The life sciences industry is evolving, and wearables and biometrics are more than just a passing trend—they’re tools that address real challenges. By simplifying compliance, streamlining operations and improving the day-to-day experience for employees, these technologies have the potential to reshape how manufacturers approach their work.

But like any tool, their impact depends on how you use them. With thoughtful planning and a focus on alignment—both with existing systems and with your people—wearables and biometrics can become powerful assets in the push for greater efficiency and reliability.

References

1. https://btlaw.com/insights/news/2024/us-healthcare-life-science-industries-face-rising-compliance-pressures

As a global technical director and chief enterprise architect at Rockwell Automation, Matt Weaver has over a decade of experience in delivering exceptional system and digital transformation consulting services to major clients across various industries. Matt’s mission is to drive industrial innovation and transformation with data and analytics, and to empower clients to achieve their operational and business goals.