Latina 6 novembre 2013. Il General Manager di Janssen Cilag, Luca Russo, ha parlato dell'esperienza formativa della sua azienda, condivisa con Pfizer, AbbVie, Johnson&Johnson e Haupt Pharma e di come il percorso formativo sia stato fondamentale per implementare la "culture of changes"
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L'intervento di Luca Russo, General Manager Janssen Cilag al "Supply Chain Award for Apics training" di Advance School
1. Janssen Latina site
a journey to
Supply Chain Excellence
Luca Russo, General Manager
November 6th 2013
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2. Janssen Supply Chain Vision
Transforming Our World:
Delivering affordable medicines to anyone, anywhere, any day
Our Mission
Be recognized as a lean & very competitive pharmaceutical
manufacturer for J&J to bring Innovation into reality !!!
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3. Janssen Latina, Italy
Be recognized as a lean & very competitive pharmaceutical manufacturer for J&J to bring Innovation into reality !!!
Plant Space (Mfg)
• Land: 1.313.000 sq ft
• Facility Size: 591.000 sq.
ft. (including ext
technical areas)
• Facility footprint:
341.000sq. ft.
• Total covered area:
503.000 sq. ft.
Major Products
• Rispedal, Reminyl
• Invega, Incivo
• Intelence, Prezista,
Edurant
• IBL, Imodium, Motilium
• Jurnista, Tramadol
• Sporanox
• Zytiga,
• Zyrtec, Tylenol,
Benadril, Simply sleep
Utilization/Shifts/Quality
• Utilization 75% (based
on 24/7)
• 24hr*7 days shift pattern
• +1700 FG sku’s
• FDA approved since ’95
• Last 5 FDA inspections
approved
• ISO 14001 certified
• OHSAS 18001 certified
People
• People: 522.5 HC (incl.
38 global)
• Salaries: 156
• Wages: 220
• Others: 146.5
• Exempts: 118
• Non-exempts: 404,5
Sales / Production
Costs**
• Sales Supported: 4 BN$
Product Launches
• 100% on-time launches
• Capital: $ 16 MM
• Conversion Cost: $ 67
MM (excl. IT)
**(YE 2012)
*(FBP2013)
(76 in 2012)
• 24hrs rapid launches
• 2013 Launch plan:
Intelence 25 mg tabs
TMC278 25mg tabs
Prezista 800 mg tabs
Prezista Glide tabs
BG12 120mg capsules
TMC435 capsules
Canagliflozin tabs
Technology&Capabilities
• Solids:Tabs,Caps(5.7BN)
• Liquids: Shampoos,
Solutions (700 Tons, 14 MM
bottles)
• Spray powder (100Tons,
4MM cans)
• Packaging: Blisters, Bottles,
Sachets, Wallet
• High level of automation and
integration
2014 Vision
• Capacity to produce 6.2 BN
units
• Fast execution: all lines at
5x3
• Unit cost reduction of 30%
• Full supplier integration
• Excellence in compliance
and customer service
• Pipeline development:
talents and Global leaders
4. Latina
QEHS and Compliance
Quality organization productivity:
Increased flexibility to
support volume and
copmlexity growth
Quality Highlights:
One Quality System as
outcome of intellectual
Date
Audit
2007
• Saudi Arabia HA
• FDA
2009
• AIFA
• KFDA
2010
•
•
•
•
2011
• Turkish HA
• AIFA
• KFDA
2012
• Japan
• AIFA
• Kenia
2013
EHS Highlights:
• FDA
• MOCK TMC435
• Mochida
synergy with all regulations.
ANVISA
AIFA
FDA
AIFA
No Smoking Site since 2007
ISO 14001 Certified since 1999
OHSAS 18001 Certified since 2005
Sound EHS Compliance Profile
2003 MAARS 4-4-4
2006 MAARS 4-5-4
2009 MAARS Green
2012 MAARS Green
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5. Understanding Latina: “culture of change”
an History of Engagement , Change mgmt and Results
• Pharma RX, OTC,
Operating mode: Flexibility & Adaptability
•
• Global Pharma,
including Japan,
Stent coating
• Business Change
(MD)
• FDA approved
• Large complexity
• Local production
• Small complexity
•
•
•
generics, medical
devices
Best Solid center in
J&J
Process Oriented
Engaged
Organization
System Based
Compliance
• Consumer,
Techfidera, Zytiga,
Canaglifozine
• Reliable org
• Talent development
• Process centered org
732
506
523
377
322
218
150
40
1980
Local business
1990
Technology &
International
2000
2005
Center of excellence
& customer dedication
2008
2010
Launch accelerator
2012
2013
Benchmark for costs,
compliance & customer service
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10. Critical Success Factor: Innovation
The backbone of our history:Integration of People, Process & Technology
NEXT Decade
Globalization JSC
Plant Activity & Efficiency
•Must add value.
J&J Factory
MES
Shop Floor Automation
Global Q&C systems
•Must help people.
Third Decade
Regional Fill/Finish
EuRoPe2
PES (Best Practice)
Integration
Operational Intelligence (Best practice)
Second Decade
INTEGRATION
Quality & Compliance Systems
Automatic Materials Handling System
First Decade
BASEMENT
Computer Integrated Manufacturing
Electronic Batch Record System
Laboratory Integrated Manag. System
1982-1991
1992-2001
2002-2011
Decades
2012-2021
11. Customer Focus: Customer Focus
Dep Value Streams:
PLANNING
•Consumer
•Bottles
•Risperdal
•Mfg/Pkg E2E
QC
MFG
•Low vol
•Fluid Bed
•Dry Granulation •High vol
•Japan
E2E value streams:
•Pharma
•Consumer FW
•Japan
•Prezista
•Daktaryn
•Dolormin
•Tylenol s
•Narcotics
•NPI
•Launches
QA
•Pharma
•Consumer FW
•Japan
E2E VALUE STREAM
PLANNING
S
T
R
E
A
M
QA
CONSUMER FW
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P
V
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QC
MFG
C
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2
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F
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P
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F
L
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B
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D
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JAPAN
PHARMA
H
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G
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N CONSUMER
O
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L NARCOTICS
U
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ZYTIGA E
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NPI/LAUNCHES
L
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12. Critical Success Factor:People Development
• Top Management visibility
• Compensation strategy (incl. Operator)
• Global roles
• Strong connection with
University to attract top
talents (Blue Eyes)
• Internal growth & targeted
external injection
• Shop floor experience
• Job rotation (Intra-Extra Plant)
• Campus Mode
• MORE Program
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16. Business Impact of Latina in 2013
Reputation & Brand Equity
OTC Recovery
Growth
Launch the Pharm NPI pipeline
TMC435
Sustain
Reliability
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17. Deliver Customer Value
Last 5 years results:
100% on-time launches, including 24hrs launches
Cost/unit
120
100
80
60
40
20
0
2009
2010
2011
2012
2013
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18. Credo & engagement plan
Credo continue to grow
while high rotation level
and people increase
Key elements & focus areas
1.
Leadership model: “Supervisor a key role”, “more”
2.
Engagement & commitment: “People make it happen”, “Credo execution leaders”
3.
Simple, concrete & business oriented initiatives
4.
Create & sustain a positive & innovative work environment
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19. LEAN TRANSFORMATION
• Adaptive culture and flexibility, attitude to drive the change.
• Will of reshaping our future through continuous improvements.
• People People People : passion and satisfaction for the Job !
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