SUSTAINABILITY REPORT 2013-15

People Overview Self Managed Teams Mechanisation Safety Overview The Parivartan     Journey Progress on     Roadmap Incident Statistics Robust Governance Standardised     Processes Enhanced Awareness Capability Building Safety Infrastructure Safety Audits Quality Overview Top-down    Accountability Quality by Design Quality Culture     Transformation Quality Assurance Quality     Best Practices All Time Audit     Readiness Availability Overview Strategic Sourcing Risk Management Product    Rationalisation Success stories Environment Overview Roadmap Energy Management Emissions Water Waste Case Study KPIs Community Overview Focus Areas Education Livelihoods Healthcare Infrastructure     Initiatives Creating Change     Makers Productivity Overview Productivity Streams Case Study PACE Update Initiatives Engineering Excellence Overview Digitisation Automation Mechanisation Lean Manufacturing Capital Equipment Strategy Predictive Maintenance Continuous Improvement Overview Continuous     Improvement     at Work Best Practices Annexures GRI Index Acronyms Assurance Statement   Summary Report     QUALITY QUALITY BY DESIGN Overview Introduced first in IPDO in FY13, Quality by Design (QbD) has been cascaded across all our manufacturing facilities. Today, we have emerged as the thought leaders in QbD in the Indian pharma space. Our aim is to not just stay ahead of the generics manufacturers, but be comparable with the innovators. And we are happy to state that we are inching closer towards this goal by strategically investing in our people, processes and procedures. We have successfully shifted to an electronic lab environment and provided 685+ scientists across 20 Labs at IPDO with the Electronic Laboratory Notebook (ELN). Apart from raising productivity for scientists, peer reviewers, and supervisors in R&D, e-notebook ensures data integrity leading to elimination of Level 3 QOIs from DQA / FDA audits. The adoption journey of the ELN is being closely monitored to ensure speedy institutionalisation.   ELN Adoption Trend (Month-wise)   No. of Projects Formulations   No. of Projects API   Over and above the ELN technology, we continue to adopt and master advanced tools such as Failure Mode Effect Analysis (FMEA), Process Mapping, Hazard Analysis and Critical Control Points (HACCP), Hazard Operability Analysis (HAZOP), Fault Tree Analysis (FTA) and Cause and Effect Analysis (CEA). But tools are only as effective as the ability of the people who leverage them. To increase their awareness of the improvement tools and techniques, the focus in the reporting period was on capability building. We signed a contract with ASQ to train our employees in six sigma, a discipline fully aligned with the philosophy of QbD. We are committed to mass six sigma training. 96% of our 1st batch emerged as certified green belts. We also conduct in-house trainings and develop e-learning modules on a regular basis.   Capability Building Dashboard No. of Participants Six sigma basic course 150 Lean six sigma green belt 56 Lean six sigma black belt 3 Lean phase 1 130 5S awareness and implementation programme 65 MSA and process capability 45 Weekly shop floor trainings for frontline operators 388 These world-class competencies acquired by individuals will soon translate into organisational competencies, delivering tangible business results.