8 Ways Wearables Solve Life Science Challenges

By Matt Weaver, Global Technical Director and Chief Enterprise Architect at Rockwell Automation

The life sciences industry operates under immense pressure to maintain product quality, meet strict regulatory standards and optimize efficiency. Many manufacturers struggle with outdated systems and processes that slow production and increase the risk of noncompliance.

As of late 2024, only 31% of life sciences compliance and risk leaders felt “very prepared” to meet compliance and risk challenges, with 56% expecting to face more resource constraints.

Wearable devices and biometric technology offer to ease these burdens, improving compliance, accelerating workflows and supporting employee productivity. Here are eight ways these technologies are transforming operations across the industry — and what manufacturers need to know to adopt them effectively.

1. Reduce Compliance Burdens Through Automation

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 prone to errors. Wearables and biometric technologies offer a way to automate and simplify compliance while maintaining the high standards regulators demand.

2. Strengthen Security with Biometric Access Control

Biometrics such as 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 each individual, making them harder to compromise.

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.

3. Monitor Protocol Adherence in Real Time

Wearables like smart badges or wristbands equipped with proximity sensors and motion trackers can monitor whether employees are adhering to critical protocols. These logs can create an audit trail, reducing manual checks and human error, making it easier and faster for manufacturers to stay compliant and secure.

4. Eliminate Bottlenecks in Critical Workflows

Efficiency is critical in life sciences manufacturing, where delays can impact supply chains and, ultimately, patient outcomes. Yet bottlenecks persist. Wearables and biometrics help manufacturers eliminate these obstacles, shaving time off critical processes without compromising quality or safety.

5. Accelerate Batch Release Approvals

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 delay production.

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 change can shave hours or days off manual approvals.

6. Automate Data Capture and Documentation

Wearables equipped with barcode scanners or RFID readers can automatically capture data related to equipment usage, material handling or employee activities.

For example, 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 real-time accuracy reduces the risk of manual entry errors that can lead to costly investigations or recalls.

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

7. Maximize Employee Productivity

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

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 via hands-free operations, which can be useful in environments where cleanliness or safety is paramount.

8. Provide On-the-Job Real-Time Guidance

Wearables such as smart glasses can provide on-the-job support, displaying context-specific instructions directly in an employee’s field of vision. When calibrating a machine, instead of consulting lengthy manuals, a technician 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 boosts both productivity and 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. Mitigate resistance to change by demonstrating how the technologies will make employees' jobs easier and more efficient.