BRISTOL-MYERS SQUIBB IN AQUITAINE, FRANCE
Transcription
BRISTOL-MYERS SQUIBB IN AQUITAINE, FRANCE
1 Depuis KEY 1995, Bristol-Myers AN Squibb a P02/03 FIGURES P04/05 INTERNATIONALLY-ORIENTATED CENTRE OF EXCELLENCE P06/07 AN ONGOING INVESTMENT investi plus de 200 millions d’euros en POLICY P08/09 QUALITY, THE No. 1 PRIORITY P10/11 HUMAN RESOURCES AND THE ENVIRONMENT: WHAT ARE THE GOALS? Aquitaine. Des investissements dans tous les domaines d’activité, qui font du site d’Agen un outil hautement performant. UNE STRATÉGIE D’INVESTISSEMENT GLOBALE Tous les secteurs ont bénéficié, au fil des années, de cette politique systématique. Les lignes de conditionnement, très automatisées, d’où sortent les produits finis. Le contrôle qualité, avec la mise en fonctionnement en 2008 d’un laboratoire de contrôle ultramoderne. Le système de stockage, avec la construction en 1997 d’un nouveau magasin grande hauteur, qui a vu sa capacité accrue en 2002. Et la fabrication, où sont réalisés les mélanges des différents composants nécess BRISTOL-MYERS SQUIBB IN AQUITAINE, FRANCE 02 KEY FIGURES KEY FIGURES BRISTOL-MYERS SQUIBB IN AQUITAINE, FRANCE 1,400 EMPLOYEES IN GASCOGNE SITE (870), GUYENNE SITE (400) AND AT THE LOGISTICS CENTRE (130) IN 1994 UPSA BECAME A 100% SUBSIDIARY OF BRISTOL-MYERS SQUIBB. Primarily dedicated to pain relief, in particular in an effervescent pharmaceutical form, Agen has since doubled its production capacity thanks to an ongoing investment policy. It is now Bristol-Myers Squibb’s leading plant worldwide in terms of volume, as well as the biggest private employer in the Lot-et-Garonne department (47). 40 % 900 OF PRODUCTION EXPORTED SUPPLIERS, OF WHICH 30% ARE LOCAL OR REGIONAL, FOR AN ANNUAL TURNOVER OF AROUND 40 MILLION EUROS 400 200 MILLION BOXES PRODUCED IN 2011, I.E. 50% OF THE VOLUMES OF BRISTOLMYERS SQUIBB WORLDWIDE MILLION EUROS INVESTED OVER 15 YEARS 3,600 ESTIMATED INDIRECT JOBS GENERATED BY THE SITE 27 AUTOMATED PACKAGING LINES 343 FINISHED PRODUCT REFERENCES 03 04 CENTRE OF EXCELLENCE AN INTERNATIONALLYORIENTATED CENTRE OF EXCELLENCE KEY PRODUCTS MANUFACTURED AT THE AGEN SITE PAIN Dafalgan® 500 mg scored effervescent tablets Dafalgan® 500 mg capsules Dafalgan® 1 g film-coated tablets Dafalgan® 1 g effervescent tablets Dafalgan® paediatric oral solution 3% Dafalgan® 80 mg, 150 mg, 250 mg effervescent powder for oral solution in sachets Dafalgan® 80 mg, 150 mg, 300 mg suppositories Dafalgan adult 600 mg suppositories ® Daflagan codéine® scored effervescent tablets and film-coated tablets MILESTONES Efferalgan® 500 mg scored effervescent tablets D 1935 Dr. Camille Bru founded Laboratoires UPSA (Union de Pharmacologie Scientifique Appliquée / (Union of Applied Scientific Pharmacology) Efferalgan® 1 g effervescent tablets Efferalgan 500 mg tablets ® Efferalganodis® 500 mg or dispersible tablets EfferalganVitamineC® 500 mg/200 mg effervescent tablets Actiskenan®, 5 mg, 10 mg, 20 mg et 30 mg, capsules D 1951 Creation of the first manufacturing plant (Guyenne) Skenan® LP, 10 mg, 30 mg, 60 mg, 100 mg et 200 mg, prolonged release micro granules in capsules D 1970 Creation of the second plant (Gascogne) Aspirine 500 mg Vitamine C Oberlin® scored effervescent tablets D 1985-1989 Aspirine UPSA® Vitaminée C effervescent buffered, scored effervescent tablets Construction of effervescent production tower No. 1 D 1994 UPSA becomes a 100% subsidiary of Bristol-Myers Squibb D 1997 • Construction of the warehouse for raw materials and packaging components • Creation of the product development laboratory Aspirine UPSA® 500 mg et 1 000 mg effervescent tablets OVER-THE-COUNTER MEDICATION Citrate de bétaïne UPSA® 2 g (Betaine citrate), sugar-free, effervescent tablets sweetened with sodium saccharin Donormyl® 15 mg scored effervescent tablets and scored film-coated tablets Fervex®, Fervex® sugar-free and Fervex® children, granules in sachets Mucomyst® 200 mg, oral powder in sachets Mucomyst® 200 mg/5 ml, powder for oral suspension Niflugel® 2,5%, gel Nifluril® 250 mg capsules Nifluril® adult 700 mg suppositories D 1998-2000 Nifluril® children 400 mg suppositories Tower No. 3 put into production Polysilane UPSA® (dimeticone), oral gel in tube and single-dose sachets D 2007-2008 The new Quality Control laboratory and granulation module # 5.4 put into operation Upfen® 200 mg scored tablets Vitamine C UPSA® 500 mg chewable tablets Vitamine C UPSA® 500 mg exotic fruit, chewable tablets Vitamine C UPSA® 1 g effervescent tablets D 2010 Tower No. 6 and granulation module # 5.3 put into production 01_ Quality Control operation 01 CENTRE OF EXCELLENCE BRISTOL-MYERS SQUIBB IN AQUITAINE, FRANCE BRISTOL-MYERS SQUIBB’S LEADING PRODUCTION SITE WORLDWIDE The largest production site (in volume) of Bristol-Myers Squibb, an international American pharmaceutical company, is in Aquitaine. When UPSA joined the group some 60 years after its creation, Agen was already a benchmark in pain relief. Today, 1.8 million boxes of medicine leave the production lines daily, which represents, all types of products combined, an annual production of 18,000 tonnes of medicine, making Agen the global leader in the production of effervescent drugs. PAINKILLERS AND DIVERSITY OF DOSAGE FORMS Since the outset, the Agen site has effectively been dedicated primarily to painkillers. Paracetamol, aspirin, codeine combined with paracetamol and morphine derivatives help to relieve all types of pain, in many pharmaceutical forms: effervescent tablets - the emblematic dosage form of the Agen manufacturing plant - but also uncoated and film-coated tablets, capsules, suppositories, sachets and oral solutions. This variety of dosage forms meets the needs of all patient populations: infants, children, adults and the elderly. INNOVATIVE DOSAGE SOLUTIONS FOR THE BENEFIT OF PATIENTS Developing dosage solutions is another key activity of the Agen section. Created in 1997, the product development laboratory is dedicated to perfecting new formulae. Latest innovation: the launch in 2010 of a new analgesic tablet, 10% smaller than the old formula and film-coated to make it easier to swallow and thus facilitate observance for relief of chronic pain, to the patient’s benefit. 05 ”AGEN, A WORLDWIDE BENCHMARK IN PAIN RELIEF” A LOGISTICS HUB, DISTRIBUTION AND EXPORT PLATFORM Logistics is the site’s third-leading activity. Agen effectively supplies painkiller products to all of Bristol-Myers Squibb’s French and international customers. What are the goals? In France, ensuring the smooth-running supply of 23,000 dispensing chemists, 3,000 hospitals and clinics and 30 wholesale distributors, which involves storing millions of boxes, recording customer orders and ensuring shipments at the highest level of quality. Not to mention exports, mainly to Europe and Africa: 40% of the 400 million boxes produced annually are exported. Orders are honoured within a timeframe of two to four days, which is reduced to 24 hours for deliveries weighing less than 30 kg. OVER-THE-COUNTER MEDICATION, ANOTHER OF AGEN’S SPECIALITIES A total of 343 finished product references leave Agen’s packaging lines. In addition to the 246 pain relief products, there is a wide range of OTC medication intended for the minor ailments of everyday life such as colds, coughs, flu-like symptoms or digestive problems. 06 INVESTMENT STRATEGY 01 INVESTMENT STRATEGY BRISTOL-MYERS SQUIBB IN AQUITAINE, FRANCE 02 01_ Packaging Operator 05 02_ The high-bay warehouse has a 16,000 pallets storage capacity 03_ 80 employees work in the Quality Control Laboratory since 2008 AN ONGOING INVESTMENT POLICY 04 07 04_ Operator in production tower No. 6 05_ Production towers unique in the world 06_ The clover, symbol of UPSA 03 06 Since 1995, Bristol-Myers Squibb has invested over 200 million euros in Aquitaine in all fields of activity that make the Agen site a very high-performance tool. A COMPREHENSIVE INVESTMENT STRATEGY MILESTONES 15 YEARS OF INVESTING IN AQUITAINE Since Agen’s integration into Bristol-Myers Squibb’s manufacturing operations, the investment policy has involved the entire site. The following have been put into operation: D 4 production towers D 2 granulation modules D 14 new packaging lines D 1 new quality control laboratory D 1 product development laboratory D and a huge high-bay warehouse for storage and supplying the workshops with raw materials and packaging components. All sectors have benefited from this systematic policy over the years. Highly automated packaging lines where the finished products emerge. Quality control with an ultra modern control laboratory put into operation in 2008. The storage system, with the construction of a new high-bay warehouse in 1997, the capacity of which was increased in 2002. And a manufacturing unit, where the mixes of the different components required for producing each drug are carried out. At the Agen site, there are two types of manufacturing equipment: granulation modules, which operate on a horizontal process, and the production towers. FOUR NEW EFFERVESCENT PRODUCTION TOWERS These production towers, unique in the world and symbols of the Agen site’s identity, rely on a very special layout, which uses gravity to transfer the product from one step of the process to the next one. This vertical process has proved the best way to handle very large volumes. The concept of the towers, opened in 1985, was later duplicated with the start-up of new towers to meet increasing customer demand. Tower No. 6 being put into production highlighted 2010. INCREASING PRODUCTION CAPACITY AND MANUFACTURING PERFORMANCE Since its integration with Bristol-Myers Squibb, the Agen manufacturing centre has doubled its production capacity in fifteen years and improved its performance level. The most recent production towers and granulation modules are characterised by greater flexibility, which makes it possible to shift more easily from the manufacture of one product to another. IMPROVING WORKING CONDITIONS Other objectives of this ongoing investment policy: continuously improving quality and working conditions, complying with the pharmaceutical and environmental regulations in force and implementing training programmes to promote the acquisition of new skills. 08 QUALITY QUALITY BRISTOL-MYERS SQUIBB IN AQUITAINE, FRANCE 09 5 01_ Quality Control Laboratory: preparation of a gas chromatography analysis 6th floor: Raw material storage 02_ Many automatic control devices on packaging lines (cameras and barcode readers) support the respect of a crucial priority 5th floor: Automatic weighing 3 QUALITY, THE No. 1 PRIORITY 4th floor: Granulation 3rd floor: Cooling 2nd floor: Grading 01 1 2 4 6 1st floor: Final mix 7 8 9 Ground floor: Supervision of the operation 02 QUALITY: A VITAL REQUIREMENT FOR BRISTOL-MYERS SQUIBB Quality is vital because the company operates in a public health field at a very high technical level and is governed by regulatory constraints. The implemented operation is based on three major levers: D rigorous and selective purchasing processes D systematic inspections at every stage of the production cycle (see diagram): up to 60 inspections per drug! D regular audits of all management systems with regard to quality and practices within the units, carried out by Bristol-Myers Squibb and AFSSAPS(1). (1) French Health Products Safety Agency On reception, all the raw materials and packaging items are given a batch number and pallet number. The pallets are transferred to the sampling units. packaging components received with the specifications described in the registration file, the corresponding pallets are released by the computer system and become available for use in production. D 2 SAMPLING D 4 DESTOCKING AND SUPPLYING THE D 1 RECEPTION Without interrupting the supply chain, samples of raw materials and packaging components are taken for analysis by the Quality Control Department. D 3 STORAGE IN THE HIGH-BAY WAREHOUSE The pallets are transferred to the high-bay warehouse (7 levels, 16,000 locations) under a “quarantine” status. A computerised system manages all of the storage locations and is interfaced with the Enterprise Resource Planning system and Quality Management System. Once the Quality Control laboratory has tested samples and confirmed the compliance of the batch of material or WORKSHOPS This consists in delivering the components necessary to produce a pharmaceutical batch to the production workshops. Destocking is carried out based on production orders and thanks to the software that manages the storage locations; traceability is guaranteed. D 5 MANUFACTURING Effervescent tablets combine an organic acid and a carbonate base. On contact with water, this combination produces a chemical reaction resulting in an off-gassing of carbon dioxide. A complex process, organised on six levels, continues through all the manufacturing stages. D 6th floor: after being routed by pneumatic conveyors the raw materials are stored. 5th floor: the various components, sodium bicarbonate, citric acid, the active principle and sorbitol are weighed very accurately. 4th floor: after being weighed the different components are mixed, granulated and dried. 3rd floor: the temperature of the granulated powder is reduced to 20° in a cooler. 2nd floor: when cooled, the powder must be calibrated to obtain the desired granulometry. 1st floor: the last operation where additive products, flavouring and compression lubricants are added to obtain a pharmaceutical batch that is homogenised in the final mix. Ground floor: This fully automated production unit is controlled by a Tour Operator, who oversees the smooth running of the different operations and ensures good manufacturing quality of their production unit. D 6 PACKAGING The granules obtained after the manufacturing stage are conveyed to the tablet presses. The three operations: compression, primary packaging (where the product is placed in its protective envelope: tube, strip, blister pack, sachet) and secondary packaging (the drug is introduced into a box together with its instruction leaflet) are performed continuously without reloading Many automatic control devices on packaging lines (cameras and bar code readers for each item printed), combined with periodic inspections entrusted to the vigilance and professionalism of the operators and production technicians, ensure the product meets quality standards. Boxes are grouped automatically in crates and then transferred by conveyor to the pallet area, located outside the white area. D 7 PALLETISATION In a specific area, pallets of finished goods are filmed and identified, thus establishing perfect continuity in product traceability. D 8 BATCH ACCEPTANCE Each batch record is subject to final inspection by Quality Assurance. This operation ensures that the entire production and control process was conducted in accordance with established procedures and the patient will have medicines with the pharmaceutical guarantees of quality described in the registration file. D 9 SHIPPING The products are transported to the Bristol-Myers Squibb Agen distribution centre, which organises the shipment to pharmacists, hospitals, wholesalers, subsidiaries or direct export customers, the latter involving more than 100 destinations around the world. 10 HR AND ENVIRONMENT CHALLENGES BIGGEST PRIVATE EMPLOYER IN LOT-ET-GARONNE HUMAN RESOURCES AND THE ENVIRONMENT: WHAT ARE THE GOALS? 01 11 04 For the biggest private employer in the Lot-etGaronne department and one of the biggest in the Aquitaine region, the human resource goals include, in particular, training and recognition of diversity. 30,000 hours of training is provided, on average, each year to employees of the Agen site, the equivalent of 3.5 to 4% of the payroll: training on new equipment of increasing technical complexity, but also on safety and security and learning good practices in pharmaceutical manufacturing with a specific section designed to promote the continued employment of older workers, in addition to arranging work schedules, such as the possibility of no longer having to work night shifts in the workshops that run in three eight-hour shifts. 02 KEY FACTS BREAKDOWN OF THE WORKFORCE 62% MEN AND 38% WOMEN: D 53% WORKERS D 34% EMPLOYEES, TECHNICIANS, SUPERVISORS D 10% MANAGERS D 3% TRAINING AND PRE-QUALIFICATION CONTRACTS D AVERAGE SENIORITY: 13 YEARS HR AND ENVIRONMENT CHALLENGES BRISTOL-MYERS SQUIBB IN AQUITAINE, FRANCE TAKING ACCOUNT OF THE IMPACT ON THE ENVIRONMENT RENEWABLE ENERGIES AND PROTECTION OF WATER RESOURCES The Agen site’s environmental policy is part of the 2015 Sustainability programme, which sets targets for reducing greenhouse gas (GHG) emissions and consumption of resources. Bristol-Myers Squibb was the first company in the department to obtain ISO 14001 environmental certification, which has been confirmed regularly since 2001 (last follow-up audit in January 2011). Agen was one of the first sites in the Aquitaine region to sign a “kWh Equilibre” contract with EDF (Electricité De France, French Electricity Company) in 2004. Bristol-Myers Squibb agreed to pay 15% of its annual electricity consumption at a price higher than the base price to encourage production from renewable energy sources. (A commitment guaranteed by Observ’er, an international independent verifier organisation). BILAN CARBONE® AND GREENHOUSEASG (GHG) REDUCTION SUCCESSFULLY INTEGRATING PEOPLE WITH DISABILITIES Bristol-Myers Squibb takes a proactive approach to integrating people with disabilities. The signing of a three-year agreement and the establishment of disability referents has helped to increase their overall employment rate at the Agen site from 3% in 2007 to 5.15% in 2010. 03 In 2010, Bristol-Myers Squibb extended its Bilan Carbone® initiative, already conducted for its head office in Rueil-Malmaison and the medical visit activity, to the Agen site as well as to the drug distribution activity. The objective is to reduce GHG emissions by 15% between now and 2015. Optimizing the consumption of the cooling towers at the Gascogne site, recovering rainwater, replacing certain water circuits lost through closed circuits and optimising some of the manufacturing processes has reduced water consumption by 50% in 5 years. The result of the sorting and recovery policy based on a new sorting platform is that 60% of waste is now recycled as against 30% in 2008. 05 01_ Packaging operators 02_ Agen site has chosen to use an electric vehicle for its Waste Management 03_ Water cooling tower 04_ Employee of the GOTC (Global Order to Cash) Customer Service 05_ Fluid supply pipes 249081104 – 2011/09 304, avenue du Docteur Jean Bru - 47000 Agen, France Tel: (+ 33) 05 53 69 84 44 BRISTOL-MYERS SQUIBB FRANCE 3, rue Joseph Monier - 92500 Rueil-Malmaison, France Tel: (+ 33) 01 58 83 60 00 BRISTOL-MYERS SQUIBB FRANCE WEBSITE www.bmsfrance.fr INSTITUT UPSA DE LA DOULEUR WEBSITE www.institut-upsa-douleur.org VIEW THE UPSA SITE OF BRISTOL-MYERS SQUIBB ON VIDEO on your mobile with the QR Code. Download the free mobile tag reader “lynkee” at http://m.lynkee.com, scan the 2D tag with the camera of your smartphone, and discover the content on your mobile. Cover picture: Aurélie, Quality Control Technician Design: Burson-Marsteller - Photos credits: Photothèque Bristol-Myers Squibb - Vincent Colin - [email protected] - © Patrick Allard / Agence Réa BRISTOL-MYERS SQUIBB - UPSA SITE