Leveraging digital twin technology for industrial transformation: a case study in pharmaceutical technology transfer

Purpose This study explores the integration of digital twin (DT) technology within technology transfer (TT) processes, focusing on a case study involving a pharmaceutical Contract Development and Manufacturing Organization. It aims to identify barriers to effective TT, propose mitigation strategies and develop a tailored project management methodology. Design/methodology/approach The research includes a literature review of TT barriers, interviews with professionals and an analysis of agile project management methodologies (Scrum, Kanban and eXtreme Programming). DT applications were simulated to assess their potential in optimizing the production process of prefilled syringes. Findings The proposed methodology effectively mitigates TT barriers, including communication, organizational and knowledge-related challenges. Simulations demonstrated the potential of DT technology in reducing process delays and enhancing decision-making, particularly by improving resource availability rather than setup times. Research limitations/implications The methodology relies heavily on inter-organizational collaboration and a “lean” mindset. Further validation is required for broader applications, especially in complex or multi-organizational contexts. Practical implications By integrating DT technology and agile management approaches, organizations can accelerate TT processes, enhance quality and reduce completion times, leading to a more efficient resource allocation and faster Return on Investment (ROI). Originality/value This study is among the first to combine DT technology with a hybrid agile project management methodology to address barriers in TT processes. Its findings contribute to both academic research and practical applications in industrial settings.