Meda Rottapharm Ltd - a Mylan company

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Read the press release here.

Corporate Overview

Mylan is a global pharmaceutical company committed to setting new standards in healthcare. Working together around the world to provide 7 billion people access to high quality medicine, we innovate to satisfy unmet needs; make reliability and service excellence a habit; do what's right, not what's easy; and impact the future through passionate global leadership. We offer a growing portfolio of more than 2,700 generic and branded pharmaceuticals, including antiretroviral therapies on which approximately 50% of people being treated for HIV/AIDS in the developing world depend. We market our products in more than 165 countries and territories. Our global R&D and manufacturing platform includes more than 50 facilities, and we are one of the world’s largest producers of active pharmaceutical ingredients. Every member of our more than 40,000-strong workforce is dedicated to creating better health for a better world, one person at a time. Learn more at mylan.com.

Meda Rottapharm Ltd - a Mylan company

Overview
Meda Rottapharm Ltd, part of the Mylan corporation, is a medium-sized pharmaceutical manufacturing facility operating in Dublin since 1999. The company supplies pharmaceutical product globally to more than 67 markets. Rottapharm has an API plant, 4 bulk manufacturing areas and 10 packaging lines where a range of products from oral liquid drops to capsules, tablets and sachets are manufactured and packaged. The plant, which is more than 100,000 square feet, sits on 20 acres in Mulhuddart, West Dublin. We currently employ 169 people across several specialist functions.

Products
The site manufactures products across a number of therapeutic areas including gastroenterology, rheumatology and cardiovascular. The site is licensed to produce commercial pharmaceutical product and clinical trial supplies. A process development laboratory for technology transfer and improvements to existing processes is incorporated within the site.

Process
There are approximately 200 skus manufactured at the facility. The production technologies used include:

Awards

Continuous Improvement Journey
The company began using lean tools in 2006 when it initiated an OEE improvement project on a sachet filling and packaging line. Projects to lean the processes in the QC Laboratory and Quality Assurance department followed. Thereafter value stream mapping, six sigma and precision changeover tools were deployed to achieve cost and quality improvements. It was apparent after a few years that a new bottom up approach was required to realise sustainable efficiencies. At the same time market conditions began to change with increased generic competition eroding volumes and margin. The necessity to increase our product portfolio and diminish reliance on a mature product range with static or declining volumes could only be achieved by pursuing a strategy for operational excellence. Investment and new products could only be assured if the plant became globally competitive.

In 2010 a plan for transformation change was rolled out and ambitious targets set for the year ending 2013. The company outlined a vision for major productivity improvements through the site wide involvement of all employees. The introduction of TPM in July 2010 proved to be the catalyst for rapid and sustained improved performance in the plant. A full-time CI manager supported by Associates across various functions was tasked with two pilots in manufacturing and packaging areas. Early success with these pilots prompted an increase resource allocation for CI activities to accelerate the introduction of TPM across all process and support areas. The desired culture of improvement took hold leading to more initiatives covering reliability centred maintenance, single point lessons, front line operator asset care, 5S, precision changeover, visual management, A3 problem solving, leader standard work and early equipment management.

A new long term vision was set for the company in 2014 underpinned by the core purpose and values of the organisation. Systems for reward and recognition, ideas generation, employee professional development, and continuous learning were re-engineered to align with the new vision.

Achievements
Safety, Environmental and Morale

Cost/Productivity

Quality & Compliance

Customer Service and Supply


Patrick Garrahy, Managing Director   |   Phone: 00 353 1 8852702   |   Mobile: 00 353 86 8107974   |   Email: pat.garrahy@mylan.com


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