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     CONTINUOUS IMPROVEMENT CONTINUOUS IMPROVEMENT AT WORK People Productivity    |    Material Productivity    |    Machine Productivity Material Productivity Improving productivity of material at Dr. Reddy's is more than just making profits, it underpins our efforts to make medicines accessible and affordable for patients across the world. Material productivity of identified products is improved by mapping the material flow and identifying stages with yield loss. Every stage is analysed for improvement using statistical techniques. Low cost solutions such as overage reduction, providing access to HTR (hard to reach) areas, handling rejection reduction, etc. are implemented.         Curbing Losses, Yield Benefits: Role Model team, Formulations Hyderabad Plant 3 took up a project for improving the yield of Fexofenadine 180 mg Tablets at manufacturing stage, which was at 94.8% (average for FY14). Detailed process mapping and data analysis indicated that most of the yield losses occur at granulation, coating and compression stages. The actions taken include:   Granulation stage: Fixing of vent filter to Rapid Mixer Grinder and automating milling process.   Compression stage: Optimising material usage.   Coating stage: Replacing compressed air lines with larger inner-diameter air pipe to facilitate better spray pattern, and replacement of inlet air filters of coating machine for maintenance of bed temperature.   Other Examples Apex Predator Lions Team improved product yield of Metoprolol common over-coated pellets for 25, 50, 100 and 200 mg strengths of ER tablets from 97% to 99% (7.61 kg/batch).   Major impacting solutions were: Lower strength division at blending and compression stages, optimised coating parameters at sustained release stage. This resulted in generation of lesser sub-standard size pellets thereby increasing the product yield. Financial benefits - ₹3,200,000 annually.   Dreamwalk Team optimised overages of coating solution used at extended release (ER) coating stage for Dipyridamole Extended Release and Acetylsalicylic Acid Capsules thereby reducing material costs. A detailed analysis of weight build-up for drug coated pellets at 70.82% and 82.30% was performed. The results established that the ER coating solution can be reduced from 484 kg to 387 kg, thereby optimising coating material overages at ER coating stage from 40% to 12%. Annual savings from the project - ₹1,400,000.   Micro Bullets Team in QC optimised the turn-around time of analysis by altering the preparation of microbiological media like Soyabean Casein Digest Agar Media (SCDA) from daily to once in ten days by validating the hold time. An in-line analysis with pharmacopeia requirements was conducted and it was concluded that the media can be used for 10 days during routine usage. Apart from resulting in work simplification and saving of man-hours, it also reduced cost by 90%. Annual savings from the project - ₹1,168,700.