Methods to Ensure Data Integrity in a Digitised Manufacturing Environment

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Methods to Ensure Data Integrity in a Digitised Manufacturing Environment

Introduction

Ensuring data integrity in manufacturing is essential for regulatory compliance, product quality, and operational efficiency. As the industry moves towards digitisation and automation, manufacturers must implement secure data management practices to meet the stringent requirements of FDA 21 CFR Part 11, GxP standards, and Good Manufacturing Practices (GMP).

With the rise of Industry 4.0, AI-driven analytics, and real-time data monitoring, organisations must adopt advanced data integrity solutions to prevent errors, eliminate data manipulation, and ensure compliance with global regulations.

This blog, written by industry experts at Realta Technologies, explores key strategies, best practices, and cutting-edge technologies to maintain data integrity in pharmaceutical, biotech, and industrial manufacturing environments.

 

What is Data Integrity in Manufacturing?

Data integrity refers to the accuracy, consistency, and reliability of electronic records throughout their lifecycle. It ensures that manufacturing data remains secure, unaltered, and audit-ready, minimising compliance risks.

In the pharmaceutical and biotech industries, data integrity aligns with ALCOA+ principles to ensure that data is:

  • Attributable – Clearly linked to the individual responsible for data entry.
  • Legible – Stored in a readable format that remains accessible over time.
  • Contemporaneous – Recorded in real-time without delays.
  • Original – Maintained in its raw, unaltered format.
  • Accurate – Free from errors, unauthorised changes, or falsifications.

Failure to maintain data integrity can result in FDA warning letters, regulatory fines, and product recalls, making compliance-critical industries highly dependent on robust data management systems.

Key Regulatory Requirements for Data Integrity

FDA 21 CFR Part 11 – Compliance for Electronic Records & Signatures

The FDA 21 CFR Part 11 regulation governs the use of electronic records and digital signatures in regulated industries. It requires:

  • Secure data storage with access controls.

  • Audit trails to track modifications.

  • Data validation to ensure authenticity and accuracy.

  • Electronic signatures for secure approvals and regulatory submissions.

GxP (Good x Practices) – Global Compliance Framework

GxP standards (such as GMP, GCP, and GDP) outline good manufacturing, clinical, and distribution practices to ensure product safety, efficacy, and quality. These require:

  • Validated systems for collecting, storing, and analysing data.

  • Change control policies to track modifications.

  • Audit-ready documentation for regulatory inspections.

Companies that fail to comply with these standards risk regulatory penalties, production halts, and damage to brand reputation.

 

Best Practices for Ensuring Data Integrity in Manufacturing

 

1. Implementing Secure and Validated Data Management Systems

To maintain compliance, manufacturers must use validated digital solutions to collect, process, and store data.

  • Data historians like AVEVA PI System ensure centralised, secure, and real-time data storage.

  • Manufacturing Execution Systems (MES) integration prevents manual data entry errors.

  • Access control protocols restrict unauthorised modifications.

Example: A pharmaceutical company using AVEVA PI to collect batch data ensures that only authorised personnel can modify or approve records, preventing data tampering.

 

2. Establishing Automated Audit Trails & Electronic Batch Records (EBRs)

Automated audit trails improve data transparency by tracking every modification in manufacturing and quality control systems.

  • Electronic batch records (EBRs) replace paper documentation, ensuring regulatory compliance.

  • Automated change logs help identify discrepancies in data entry.

  • Real-time alerts detect anomalies in production data.

Example: A biotech firm adopting Syncade MES for batch reporting uses automated exception tracking, allowing quality teams to focus only on critical deviations.

 

3. Connecting Standalone Systems to the Manufacturing OT Network

Many manufacturing environments still operate standalone, isolated systems that are not networked into the wider Operational Technology (OT) infrastructure. These islands of automation create data integrity risks due to manual processes, lack of backups, and limited security controls.

Integrating these standalone systems into an OT network significantly enhances data integrity, security, and compliance. Key advantages include:

  • User Management via Domain Active Directory and Windows Integrated Security

    • Standardised access control with centralised user authentication.

    • Reduces risks of unauthorised system modifications.

    • Improves regulatory compliance with secure login credentials.

  • Automated Data Collection

    • Eliminates manual data entry errors.

    • Ensures real-time tracking of critical manufacturing parameters.

    • Enhances reporting accuracy for regulatory audits.

  • Automated System Backups

    • Prevents data loss due to system failures or cyber threats.

    • Ensures data redundancy for compliance and business continuity.

  • Disaster Recovery and Business Continuity

    • Enables rapid recovery of manufacturing data in case of hardware failure or security breaches.

    • Ensures minimal downtime and regulatory compliance.

4. Integrating Digital Manufacturing Systems for Seamless Data Flow

To ensure complete traceability, manufacturers must integrate SCADA, MES, ERP, and IoT platforms for seamless data exchange.

  • OPC UA, MQTT, and BACNet protocols support real-time data transmission.

  • Cloud-based manufacturing solutions enable remote monitoring.

  • Automated data reconciliation minimises human intervention.

5. Training Employees on Data Security & Compliance

Regular training ensures that staff understand data security protocols and regulatory compliance requirements.

  • Quarterly compliance training sessions reinforce best practices.

  • Standard Operating Procedures (SOPs) outline data entry and validation processes.

  • Internal audits assess adherence to ALCOA+ principles.

Example: A biotech firm conducts quarterly data integrity training, reducing compliance errors by 30% over a year.

 

How Realta Technologies Helps You Ensure Data Integrity

At Realta Technologies, we specialise in implementing data integrity solutions tailored for pharma, biotech, and regulated manufacturing environments.

 

Our Expertise Includes:

  • AVEVA PI System & Data Historians – Secure storage and real-time access to process data.

  • MES & ERP Integrations – Seamless data flow between manufacturing systems.

  • Electronic Batch Records (EBRs) – Automated batch reporting with audit trails.

  • Data Analytics & Predictive Quality Control – Advanced monitoring using PowerBI & SEEQ.

  • Regulatory Compliance Support – Ensuring adherence to FDA 21 CFR Part 11 and GxP standards.

By working with Realta Technologies, manufacturers can ensure compliance, improve data security, and enhance operational efficiency.

Contact Realta Technologies today to discuss how we can help strengthen your data integrity strategy.

 

Conclusion

Data integrity is a critical factor in modern manufacturing, ensuring compliance with regulatory standards and improving product quality. By implementing secure digital systems, predictive analytics, and AI-driven automation, manufacturers can prevent compliance failures and data inconsistencies.

 

Realta Technologies provides the expertise, tools, and solutions required to establish audit-ready, high-integrity data systems for pharmaceutical, biotech, and industrial manufacturing sectors.

 

Learn more about our solutions here: https://realtatechnologies.com/services/

Ensure your manufacturing data meets the highest standards of integrity and compliance. Contact Réalta Technologies today for expert solutions that give you complete peace of mind in regulatory compliance and data security:

 

Phone: +353 21 243 9113

Email: [email protected]

Methods to Ensure Data Integrity in a Digitised Manufacturing Environment

Introduction

Ensuring data integrity in manufacturing is essential for regulatory compliance, product quality, and operational efficiency. As the industry moves towards digitisation and automation, manufacturers must implement secure data management practices to meet the stringent requirements of FDA 21 CFR Part 11, GxP standards, and Good Manufacturing Practices (GMP).

With the rise of Industry 4.0, AI-driven analytics, and real-time data monitoring, organisations must adopt advanced data integrity solutions to prevent errors, eliminate data manipulation, and ensure compliance with global regulations.

This blog, written by industry experts at Realta Technologies, explores key strategies, best practices, and cutting-edge technologies to maintain data integrity in pharmaceutical, biotech, and industrial manufacturing environments.

 

What is Data Integrity in Manufacturing?

Data integrity refers to the accuracy, consistency, and reliability of electronic records throughout their lifecycle. It ensures that manufacturing data remains secure, unaltered, and audit-ready, minimising compliance risks.

In the pharmaceutical and biotech industries, data integrity aligns with ALCOA+ principles to ensure that data is:

  • Attributable – Clearly linked to the individual responsible for data entry.
  • Legible – Stored in a readable format that remains accessible over time.
  • Contemporaneous – Recorded in real-time without delays.
  • Original – Maintained in its raw, unaltered format.
  • Accurate – Free from errors, unauthorised changes, or falsifications.

Failure to maintain data integrity can result in FDA warning letters, regulatory fines, and product recalls, making compliance-critical industries highly dependent on robust data management systems.

Key Regulatory Requirements for Data Integrity

FDA 21 CFR Part 11 – Compliance for Electronic Records & Signatures

The FDA 21 CFR Part 11 regulation governs the use of electronic records and digital signatures in regulated industries. It requires:

  • Secure data storage with access controls.

  • Audit trails to track modifications.

  • Data validation to ensure authenticity and accuracy.

  • Electronic signatures for secure approvals and regulatory submissions.

GxP (Good x Practices) – Global Compliance Framework

GxP standards (such as GMP, GCP, and GDP) outline good manufacturing, clinical, and distribution practices to ensure product safety, efficacy, and quality. These require:

  • Validated systems for collecting, storing, and analysing data.

  • Change control policies to track modifications.

  • Audit-ready documentation for regulatory inspections.

Companies that fail to comply with these standards risk regulatory penalties, production halts, and damage to brand reputation.

 

Best Practices for Ensuring Data Integrity in Manufacturing

 

1. Implementing Secure and Validated Data Management Systems

To maintain compliance, manufacturers must use validated digital solutions to collect, process, and store data.

  • Data historians like AVEVA PI System ensure centralised, secure, and real-time data storage.

  • Manufacturing Execution Systems (MES) integration prevents manual data entry errors.

  • Access control protocols restrict unauthorised modifications.

Example: A pharmaceutical company using AVEVA PI to collect batch data ensures that only authorised personnel can modify or approve records, preventing data tampering.

 

2. Establishing Automated Audit Trails & Electronic Batch Records (EBRs)

Automated audit trails improve data transparency by tracking every modification in manufacturing and quality control systems.

  • Electronic batch records (EBRs) replace paper documentation, ensuring regulatory compliance.

  • Automated change logs help identify discrepancies in data entry.

  • Real-time alerts detect anomalies in production data.

Example: A biotech firm adopting Syncade MES for batch reporting uses automated exception tracking, allowing quality teams to focus only on critical deviations.

 

3. Connecting Standalone Systems to the Manufacturing OT Network

Many manufacturing environments still operate standalone, isolated systems that are not networked into the wider Operational Technology (OT) infrastructure. These islands of automation create data integrity risks due to manual processes, lack of backups, and limited security controls.

Integrating these standalone systems into an OT network significantly enhances data integrity, security, and compliance. Key advantages include:

  • User Management via Domain Active Directory and Windows Integrated Security

    • Standardised access control with centralised user authentication.

    • Reduces risks of unauthorised system modifications.

    • Improves regulatory compliance with secure login credentials.

  • Automated Data Collection

    • Eliminates manual data entry errors.

    • Ensures real-time tracking of critical manufacturing parameters.

    • Enhances reporting accuracy for regulatory audits.

  • Automated System Backups

    • Prevents data loss due to system failures or cyber threats.

    • Ensures data redundancy for compliance and business continuity.

  • Disaster Recovery and Business Continuity

    • Enables rapid recovery of manufacturing data in case of hardware failure or security breaches.

    • Ensures minimal downtime and regulatory compliance.

4. Integrating Digital Manufacturing Systems for Seamless Data Flow

To ensure complete traceability, manufacturers must integrate SCADA, MES, ERP, and IoT platforms for seamless data exchange.

  • OPC UA, MQTT, and BACNet protocols support real-time data transmission.

  • Cloud-based manufacturing solutions enable remote monitoring.

  • Automated data reconciliation minimises human intervention.

5. Training Employees on Data Security & Compliance

Regular training ensures that staff understand data security protocols and regulatory compliance requirements.

  • Quarterly compliance training sessions reinforce best practices.

  • Standard Operating Procedures (SOPs) outline data entry and validation processes.

  • Internal audits assess adherence to ALCOA+ principles.

Example: A biotech firm conducts quarterly data integrity training, reducing compliance errors by 30% over a year.

 

How Realta Technologies Helps You Ensure Data Integrity

At Realta Technologies, we specialise in implementing data integrity solutions tailored for pharma, biotech, and regulated manufacturing environments.

 

Our Expertise Includes:

  • AVEVA PI System & Data Historians – Secure storage and real-time access to process data.

  • MES & ERP Integrations – Seamless data flow between manufacturing systems.

  • Electronic Batch Records (EBRs) – Automated batch reporting with audit trails.

  • Data Analytics & Predictive Quality Control – Advanced monitoring using PowerBI & SEEQ.

  • Regulatory Compliance Support – Ensuring adherence to FDA 21 CFR Part 11 and GxP standards.

By working with Realta Technologies, manufacturers can ensure compliance, improve data security, and enhance operational efficiency.

Contact Realta Technologies today to discuss how we can help strengthen your data integrity strategy.

 

Conclusion

Data integrity is a critical factor in modern manufacturing, ensuring compliance with regulatory standards and improving product quality. By implementing secure digital systems, predictive analytics, and AI-driven automation, manufacturers can prevent compliance failures and data inconsistencies.

 

Realta Technologies provides the expertise, tools, and solutions required to establish audit-ready, high-integrity data systems for pharmaceutical, biotech, and industrial manufacturing sectors.

 

Learn more about our solutions here: https://realtatechnologies.com/services/

Ensure your manufacturing data meets the highest standards of integrity and compliance. Contact Réalta Technologies today for expert solutions that give you complete peace of mind in regulatory compliance and data security:

 

Phone: +353 21 243 9113

Email: [email protected]

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