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Pharmaceuticals
Rottapharm Reaps Rewards
Pharmaceutical company Rottapharm Madaus recently received
recognition for excellence across all aspects of manufacturing.
progress during the last He added: “The
year is significant.” Continuous Improvement
Rottapharm also won the award recognised excel-
SMA e-Factory Hall of lence in motivating employ-
Fame award, with judges ees at all levels to reduce
stating: “This company has waste from business
T
demonstrated a strong processes.
Pat Garrahy and Dr Enzo Lacchini, Corporate Technical Director business case of World “Rottapharm embarked
Rottapharm Madaus, with Rottapharm staff at the awards Class Manufacturing. They on a continuous improve-
he Sixth Annual successfully deploy numer- ment programme in 2010
S t r a t e g i c ous IT solutions, delivering centred primarily on a TPM
Manufacturing the business a competitive initiative.
Awards 2012 ceremony advantage to ongoing con- “This programme is clear-
took place at the Swissôtel tinuous improvement pro- ly aligned to Rottapharm’s
Düsseldorf as part of the grams. With a burning commitment to world class
European Manufacturing ambition to reduce their manufacturing methodolo-
Strategies Summit. Over carbon footprint, this com- gies. It was borne out of the
200 industry leaders gath- pany is a clear winner.” realisation that improved
ered to hear the announce-
ment of the winners.
“ annual
The “The annual awards are
given across a number of
competitiveness could best
be sustained by integrating
The Strategic awards are categories associated with improvement activities with
Manufacturing Awards excellence in manufactur- the day to day work within
were created to celebrate given across ing operations,” explained the plant. TPM has been key
excellence in all aspects of Pat Garrahy, Managing to new ways of working
manufacturing including a number of Director. where internal processes
lean, innovation, opera-
categories “Rottapharm Madaus are constantly reviewed and
tional excellence and sus- Ireland made submissions improved to reduce waste.”
tainability of companies associated in three categories:
and individuals in the man- Outstanding Achievement
with
Best Practice
ufacturing industry. in Continuous The Factory Hall of Fame
Improvement, Green and award recognises leader-
Continuous excellence in Sustainable Energy and ship in manufacturing inno-
Improvement manufacturing” Factory of the Future. The vation and best practice.
Rottapharm Madaus company was shortlisted in The successful deployment
Ireland picked up the all three categories. of numerous IT solutions at
Outstanding Achievement “Rottapharm was Rottapharm to reduce non
in Continuous Improvement declared the winner of the value adding activities and
Award, with comments on Continuous Improvement support greater participa-
the win including: “The sig- Award. In addition tion in Continuous
nificant thing about this Rottapharm won the Improvement initiatives
entry is the involvement Factory Hall of Fame award earned the commendation
and engagement of which is given to the 'win- of the judging panel.
employees. Their KPI ner of the winners'.” “Solutions were imple-
Manufacturing Ireland Feb 2013 11

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Pharmaceuticals
mented for Warehouse for a TPM initiative. This
M a n a g e m e n t , Dublin Operation was followed in 2012 by
Manufacturing Execution, Rottapharm is based in winning the overall MEETA
Computerised Maintenance Damastown Industrial award in the Maintenance
Management, Asset Park, Mulhuddart. Technology category.
Performance Management Construction of the plant Energy efficiency also
and Energy Monitoring,” was completed on a green- became a major part of
stated Mr Garrahy. field site in 1999. A manu- Rottapharm's focus in
“These systems were in facturing authorisation recent years. The company
the main implemented by from the IMB for the pro- was nominated for the 2012
in-house project teams and duction of pharmaceutical SEAI Energy Efficiency
provide accurate, real time Pat Garrahy receiving the
product was granted in Awards in the large energy
information to management award for Outstanding December of that year. user category. The submis-
and factory floor person- Achievement in Continuous That same year, it obtained sion highlighted the reduc-
Improvement at the Strategic
nel. the ISO 9002 certification tion over a three-year peri-
Manufacturing Awards
“The organisation is now for the production of med- od of 50 per cent in energy
well advanced in its objec- ical devices. The operation cost per pack through vari-
tive of eliminating paper in West Dublin manufac- ous green and sustainable
based systems from all tures a range of capsule, energy initiatives.
areas of the plant.” sachet and tablet formula-
Projects recently com- tions in addition to the API Rottapharm Madaus
pleted at Rottapharm Crystalline Glucosamine Group
included a LIMS implemen- Sulphate. The company’s Rottapharm Madaus is a
tation and an electronic leading product DONA (the multinational pharmaceuti-
forms workflow system. original Glucosamine cal group headquartered in
These systems comple- “External Sulphate) is manufactured Monza, Italy. It employs
ment the electronic batch in sachet and capsule more than 2,000 people
records and computerised validation of forms for markets in worldwide. It is active in
paperless maintenance Europe, Asia and South over 80 countries operating
system implemented in this kind is America. Currently the in the pharmaceutical, per-
prior years. company employs 150 peo- sonal care, nutraceuticals
Organisations such as
a huge ple. In 2008 the plant and medical device sec-
Volkswagen, L’Oreal and obtained certification to tors. The company was
Premier Foods were nomi-
endorsement Gold level in the ETP, founded in Italy in 1961 by
nated for the 2012 awards ‘Excellence Through Professor Luigi Rovati,
of the
and winners in previous People’ standard. This is an President of the company.
years included Toyota and initiative promoted by the Commenting on the
contribution
Heineken. “These awards Government to recognise Strategic Manufacturing
reflect the dedication and high standards in the man- Awards Professor Rovati
commitment of all our agement of human praised the commitment of
employees who have made by our resources. The objective is the employees to be the
worked with such passion to get organisations to look best in their field: "The
to reach the highest stan- people” at their people as a key Dublin plant has reached
dards of operational excel- source of competitive this high level through the
lence,” concluded Mr advantage. deployment of modern
Garrahy. In 2011, the plant manufacturing techniques
“External validation of received two new acco- and innovative technologi-
this kind is a huge endorse- lades at the MEETA cal systems. The efforts of
ment of the contribution Awards. It won the overall the staff to continually
made by our people to award in the Maintenance improve the operations in
improved plant perform- Management category and Ireland is worthy of the
ance.” a Certificate of Excellence highest commendation.”
Manufacturing Ireland Feb 2013 13