gms engineering ehs town hall-april2010final

8/3/2019 GMS Engineering EHS Town Hall-April2010final

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GMS Engineering & EHSTown Hall

April 2010


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Agenda

1. Introduction

2. GMS Engineering Strategic Themes

3. EHS Key Programmes

4. Engineering Around GMS:

Engineering Capability

ETC India

Maintenance Efficiency Consumer Health

5. Recap

6. Q and A


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GMS Above-Site Engineering & EHS organisation

GMS

Engineering &EHS Head

GMSEngineering

ServicesLead

OperationalEngineeringCoE

PrimaryControl and Instrumentation

CoE

PrimaryOperationalEngineering

Shared Services

EngineeringTechnical

Shared Services

Site ServicesShared Service

EnvironmentalPerformance

CoE

Primary EHSSharedService

GMS EHSServices

Lead

EHSShared Sevice

PrimaryProcess

Safety Project

Capital ProjectsShared Service

Programme

ManagementProjectControl

RegionalProject

Managers

RegionalProject Leads

CapitalProcurement

EngineeringProject

ManagementPool


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GMS Engineering Strategic Themes

Businessvaluefrom

capital

OneEngineeringcommunity

Tracking

performance

Underpinningsustainability

IncreasingMaintenanceeffectiveness

Engineering

Safety andstandards

BuildingGlobal

EngineeringCapability

CUT


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GMS Engineering Links to GSK Strategy

Underpinningsustainability

Engineeringsafety andstandards

Increasingmaintenanceeffectiveness

TrackingPerformance

Buildingglobal

engineeringcapability

OneEngineeringCommunity

BusinessValue from

Capital


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GMS EHS Programmes


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Key EHS Programmes

1. Living Safety

2. Process Safety

3. Zero Access

4. Respirator Free Red Task Elimination

5. Professional Certification


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Living Safety Underpinning all EHS PerformanceImprovement

What are the key elements of Living Safety?

Train Facilitators and conduct Gap Analysis with SiteLeadership Team

Appoint a Site Steering Team

Use Workshops and/or Questionnaires to explain thedesired behaviours and identify gaps

Select actions from existing Toolkit or generate ownsolutions

What are the key behaviours?

Standards

Communication

Risk Management

Involvement

What is expected of EHS/Eng Professionals? Participate and get involved understand the Living

Safety Programme at your site

Set high standards

Lead by example

Challenge risk


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Process Safety EHS and Engineering DrivingImprovement

Primary Technology Sites

The process safety programme implemented in 2009 continues with a focuson risk mitigation and reduction

Governed through the API Manufacturing EHS Board

Standardised site Process Safety Plans in place and tracked

Five Process Safety Performance Indicators (PSPIs) tracked monthly

CAPA remediation and PS risk reduction (ongoing)

Secondary and Consumer Sites

A standardised Process Safety assessment and control programme is beinglaunched during 2010

This will be focused on needs of Secondary and Consumer Operations

Qtr 2 2010 Questionnaire / Survey to take place

Qtr 3 2010 Detailed plan development (e.g. Dust Collectors, Fluid BedDryers)


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Zero Access

Programme support in place

Chris Hurst GES 110 Machinery Safety Ed Rohowetz and Ricky McGowan now

part of GMS EHS Shared Service -supporting Zero Access

3-year project with the followingdeliverables

1. Upgrade physical guarding to ZeroAccess standard. (Engineering)

2. Upgrade Lock-out/Tag-out (LOTO).(Engineering / Operations)

3. Enhance site capability and systems toensure improvements are sustained.(Living SafetyBehaviours/Systems/Training)

Programme Success depends on Living

Safety Values


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Forecast Activities for Next Period

Respirator Free - Red Task Elimination 2010

Long term goal 80% Respirator Free by 2012. Currently at 52%

Target for 2010

Elimination of RPE Red Tasks (~300 tasks) Key items for sites

1. continue to complete OH monitoring,

2 address red tasks

3. update Tracker

Advice available from Ruzen Castenda CHS; Ritesh Patel ABEMS; Russell Collins - PhLGSDamien Boyd EHS SS and Bina Lowcock EHS SS

Currently programme is on track

7%

35%

17%

30%

10%

1%

GMS Task Status Summary end March 2010

(~3000 tasks)Uncharacterised

Respirator free

Respirator free - partiallycharacterised

Ok with RPE

Improvement needed

Tracker incomplete


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Professional Certification

Current Situation

50% of EHS professionals in GMS do not holdappropriate professional qualifications

60% are not certified members of relevantprofessional bodies

This is primarily due to lack of local professional

qualifications of an international standard in manycountries

3-year project with the following deliverables

All GMS sites must ensure access to at least one

certified professional in relevant EHS disciplinesby 2012

Qualifications and memberships must beapproved by GSK to ensure appropriate standard

Action plan must be agreed with divisional EHS

Director and/or GMS Medical Director


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Building GlobalEngineering Capability


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GMS Engineering - Changing landscape

Russia

China

India

DMEA

MENA

SSA

Latina

AsiaPacific

GMS Engineering Capability

Company/Site acquisition

Steifel / BMS Pakistan/Egypt

MENA and AP expansion inmanufacturing footprint

Strategic partnerships / Product Acquisition

Where we gain access to brandse.g. Aspen

Where we gain access to sitefootprints with brands

GMS Supply Divisions 4 : 3

GSK Strategy

Regional Capability Engg/EHS Alignment PS Capability Reducing Capex Plan Network Changes EM Growth CCERP/Sustainability


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GMS Engineering Building Global Capability

JobRotation

RegionalCapability

InternationalGraduate

Schemes

Engineering

Structure

& Systems

TalentManagement

BuildingGlobal

EngineeringCapability

EXECUTION

Five Key Areas of Development:

Reviewed by GMS ELT in March 10

Kicked Off Activity in Q1 2010


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EngineeringTechnical Centre


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GMS Engineering

Who Expertise Projects

ETC Core Team

Aman Kapoor Process engineering, VOC and containment Nashik, Thane,

Kanheya Mehrotra Efficient ETC operation & Defining Business Need for GSK GMS

Rajinder Tewari Project Mgmnt, Utilities and MEG Expert Gurgaon

Ravinder Bhardwaj HVAC and mechanical and zero access Indonesia, Nashik

Ritu Bhatnagar Process Architect: Secondary, Labs & offices Sonepat, Nashik

Rupa Kishore Project Manager for FES Nashik

Syamal Kundu Process Engineering: Secondary & API Cork, Irvine, Montrose

Sandeep Gupta Low cost sourcing & second hand equipment GMS

Umesh Mishra Planning & project Controls Indonesia, Thane NashikETC Extended Team

Anil Relan Pharma Engineering Expert : Secondary, API & steriles Bangladesh

Ashutosh Revo Mechanical Equipment Expert Sonepat

P K Verma Civil & Structural Expert Algeria, China

M K Vardia Electrical Expert Sonepat, Nashik

Extra resources

3-4 Civil, Electrical, Process, Environmental Engineers

+ 8

10 Draughtsmen

ETC Capability Chart

ETCEngineers


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CorkJurongThane

Montrose

IrvineNashik

Emergency ventingcalculations.

Facility Master

Planning.

SonepatNashik

PulogadungChittagong

Gurgaon

Studies for newfacilities,

expansionprojects, or

modifications.

ETC engagement with GSK

Feasibility/Concep

t

Inception Future

PoznanBrasov

MemphisUlverstonPort Fairy

BaddiExpanding remit

both geographicallyplus into new areasof site and project

support.


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ETC Efficiency improvement

ETC applying GES304 consistently across GMS sites. Shared service efficiency gains as same type of work is repeated.

19/hr vs Western rates of 60-80/hr.

41

31

26

17

0

5

10

15

20

25

30

35

40

45

Cork Montrose Irvine Thane

GES304 Emergency VentingHours per calculation


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Maintenance Efficiency ProgrammeConsumer Health Ph1


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Background

7 CH sites account for ~65% of maintenance activity and cost in CHdivision (~26m pa).

(Total Cost of Maintenance Site OPEX) ~ 16% for this group.

World Class Benchmark 6% - 10%

Memphis Diagnostic Pilot Apr-09

Phase 1 Project approved at OPEC Nov-09

Potential Opportunities

MaintenanceCost Reduction

IncreasedOEE

Size of Opportunity - 5m pa

MemphisClifton

St LouisAiken

DungarvanSlough

Maidenhead


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Maintenance Diagnostic

PreparationDiagnostic

EventImplementation & Benefit Delivery

4 weeks 1 week 12 18 months

Follow-Up Supportfrom CoE Critical to

Success

Benefit Tracking through

CHS and OPEC

St Louis Diagnostic Event

Typical Opportunities Labour efficiency (headcount reduction) Management and control of R&M spend Reliability improvement & OEE gains Spare parts management Work planning & scheduling


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Successes So FarSuccesses So Far

Benefit opportunities identified in line with 5m target.Generic tools and solutions developed or deployed:

Maintenance process flow map

Equipment criticality tool

Reliability based PM techniqueEngineering Failure Rate KPI

Examples of first benefits delivered:

Clifton OEE 39% 48%

Memphis Lopez OEE 20%

45%Aiken 1 FTE reduction in parts store

Clifton 3FTE reduction in maintenance team

Memphis 1FTE reduction on FLT maintenance


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Future Plans

CH Phase 25 further site diagnostics in 2010

Alcala diagnostic event completed

ABEMS Secondary Sites2 site diagnostics completed in 2009

9 further site diagnostics in 2010

PhLGS Secondary Sites2010 CoE support focused on Failure Rateimprovement


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Town Hall Key Themes

Building Global Capability

Professional Accountability

Individual Leadership Shadow


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Questions?

gms engineering ehs town hall-april2010final

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