Business Continuity Planning

Business Continuity Planning
Always be prepared for the unexpected!
Get back in business asap!
Ir. Jan van Aarle
Dr. Ir. Johan Maes
Agenda
1. History (from J&J)
2. Business Continuity Planning (BCP)
3. BCP Certification Process
4. BCP manual
5. Critical success factors
6. Description of testing with in Chemical (API) manufacturing
Johan Maes
History
• Aftermath September 11, 2001
• Russ Deyo: Executive Committee sponsor
– Start BCP program = Jan. 03 letter to implement BCP
by YE 2003
In January 2002, I wrote to you about the formation of the Emergency
Preparedness Task Force. This enterprise-wide initiative was established in
response to September 11th and subsequent terrorist threats and was one
of several steps taken to help ensure that the people, facilities and products
of the Johnson & Johnson Family of Companies remain secure and safe.
• BCP will become institutionalized and continuously assessed Corporate wide process
Annual Certification requirements
Corporate has formalized BCP roles and process
Agenda
1. History
2. Business Continuity Planning (BCP)
3. BCP Certification Process
4. BCP manual
5. Critical success factors
6. Description of testing with in Chemical (API) manufacturing
Johan Maes
What is Business Continuity?
Business Continuity Planning (BCP) is a process where
clear plans are developed to:
Safeguard employees
Protect assets
Manage risk (including insurance premium
reductions)
Provide for continued supply of products and
services following a catastrophic event
Sustain market share / revenue flow
Identify significant existing exposure
Define mitigation steps and action items
Objective: “Stay in Business after a Disaster”
BCP Elements
Three core elements:
Emergency Response (0 - 2 hours)
Incident Management (0 - 48 hours)
Operations Recovery (0 - 24 months)
Agenda
1. History
2. Business Continuity Planning (BCP)
3. BCP Certification Process
4. BCP Binder
5. Critical success factors
6. Description of testing with in Chemical (API) manufacturing
Johan Maes
Business Continuity Planning Process
Company
Strategic Plan
Workshop
(Training)
Critical Suppliers
&
External Mfgs.
Corporate BCP Review/Assessment
Plan
Development
Sector
Alignment
Meeting
Step 2
BCP Review
(Periodic/Change)
Draft
BCP
Tabletop
Exercise
Certification
Recertification Process
Update
BCP
Tabletop
Exercise
Recertification
Implement
BCP
Agenda
1. History
2. Business Continuity Planning (BCP)
3. BCP Certification Process
4. BCP manual
5. Critical success factors
6. Description of testing with in Chemical (API) manufacturing
Johan Maes
BCP Binder
1. Introduction (No Tabs)
2. Emergency Response
3. Incident Management
4. Operations Recovery
5. Appendices
Emergency Notifications and Response Teams
Critical Area Map JJPRD
BCP Binder
1. Introduction (No Tabs)
2. Emergency Response
3. Incident Management
4. Operations Recovery
5. Appendices
Emergency Response: Red (0 - 1hr)
1.
2.
3.
4.
Emergency Response flowchart
Evacuation Procedures
Initial Support
Response Scenarios
The different responsible departments
(security, emergency response team,…)
Fire Brigade Responsibility
BCP Binder
1. Introduction (No Tabs)
2. Emergency Response
3. Incident Management
4. Operations Recovery
5. Appendices
Incident Management: Yellow (0 - 48 hr)
Focus on
Communication
The different responsible departments: CMT,
Business Units, Site Resources and Support
1. Roles and Responsibilities
2. Public Communications
3. Crisis Plans: Human Resources, IT, Records Management and Risk Management
BCP Binder
1. Introduction (No Tabs)
2. Emergency Response
3. Incident Management
4. Operations Recovery
5. Appendices
Operations Recovery: Green (1 day - 18 months)
The different responsible departments:
Communications, HR, IM, Engineering,…
Assessment
Start Full Recovery
Operations Recovery: Action Plans (RAP)
WHAT
RAP Sheets: shows for each time slice
WHAT should be done and HOW these
activities should be carried out
Responsible departments
BCP Binder
1. Introduction (No Tabs)
2. Emergency Response
3. Incident Management
4. Operations Recovery
5. Appendices
– List of Alternate Capacity
– List of Critical Equipment
– List of Key Materials /Supplies
– IT Contingency Plan
Agenda
1. History
2. Business Continuity Planning (BCP)
3. BCP Certification Process
4. BCP manual
5. Critical success factors
6. Description of testing with in Chemical (API) manufacturing
Johan Maes
Critical success factors
• Each segment of the plan is the responsibility of each individual
department and its key managers
• Scoring of the plan and the table top exercise
• Management commitment - Management involvement
• Clear roles and responsibilities
• Extended toolkit of J&J Corporate
– Template plan
– Action oriented
– Simple to use – to keep up to date
Agenda
1. History
2. Business Continuity Planning (BCP)
3. BCP Certification Process
4. BCP manual
5. Critical success factors
6. Description of testing with in Chemical (API) manufacturing
Johan Maes
Worldwide Chemicals
• A group of 4 API manufacturing sites across the world
–
–
–
–
Geel – Belgium
Cork – Ireland
Schaffhausen – Switzerland
Athens – GA, USA
• Each having a specific product portfolio but standard equipment
platforms
– Fine API production, synthesis production
– Batch processes
• All sites working in a very regulated environment
– Safety perspective
– Regulatory perspective
Our implementation of BCP (1/2)
• A global process across the network
– Local part for External Manufacturing (EM) and Internal Manufacturing
(IM) (site specific)
– Global part for business recovery (BR)
• EM & IM regular drills throughout the year on every site
• External assessment for 1 site on a rotating basis
• Other sites do internal assessment every year
• The assessment
– Simulation versus tabletop for EM & IM
– Virtual or real for BR
• Results are shared across the sites
Our implementation of BCP (2/2)
Emergency
Response
Incident
Management
Business
Recovery
Appendices
Owned by the EHS department
Based on existing procedures and processes
Set up as OCT / DCT
Integrated process
Owned by global supply chain
Goal is to secure supply to the market
Using existing internal resources and
option to use external partners
Run by global SC group
The scenario
Scenarios for review and verification of the Business Continuity Plan
Scenario I
Explosion and fire in Plant III
Due to incorrect dosing during a Friedel-Craft reaction, an exothermic reaction is
caused.
As a result of the uncontrollable reaction the reactor explodes.
At the time of the explosion various production activities are taking place at the
reactor level.
Pure raw materials are being pumped from the pure tank park and 2500 liters of
highly flammable fluids are being pumped out of 200-liter drums into a reactor
alongside the exploding reactor.
The resulting explosion triggers a chain of events, domino style: escape of solvents to
the outdoor environment, product spillage from broken pipelines, smashed glassware,
etc.; all combine to produce an explosive mixture at the various lower levels of Plant
III.
A second explosion at these lower levels causes very severe damage in Plant III,
making the plant non-operational. These explosions also cause severe damage to the
nearby pipe rack. Because of the severe damage to the pipe rack, pure raw materials
can no longer be pumped to Plants I and II and Plant IV for a considerable length of
time.
Detailed scenario
14.40
BBW aan OCT met situatieschets
DCT Info
- Plant III
o tweede explosie op 7 meter
o grote verwoesting aan installaties
o twee medewerkers worden vermist
- Pijpen rek ter hoogte plant III en tankpark
o gestart met het blussen van de plasbrand
o koeling voor tankpark is voorzien
- Distributie centrum chemisch magazijn
o spill van aceton +/- 50 liter
o explosie gevaar in de zone van de spill
o twee vermiste personen gevonden, nog geen
namen bekend
o we moeten beide slachtoffers nog ontzetten
14.XX
Golf aan OCT
Verschillende hulpdiensten zullen zich aanmelden
- Brandweer Westerlo
- Brandweer Mol
- Brandweer Balen
- ziekenwagen Geel
Simulation
The Business Recovery tabletop
• Meet with the global supply chain group
• Inform the team about the incident
• Start the process of what is needed to secure supply taking into
account the lost capacity
–
–
–
–
–
Which products are critical
Which capacity is affected, hence which products
What are the alternative production options for those products
What capacity can we free up
Who do we have to inform
• Internal management
• Regulators
– …
The scoring grid
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