Insider Look at FOYA Education Session and Winners
Attendees packed the room for this year’s Facility of the Year Education (FOYA) Session, moderated by Dave DiProspero, Chair of the FOYA Committee (below on left). The interactive FOYA Education Session gave attendees rare insight into the FOYA Category winners as they discussed their winning projects.
Dr. Takeshi Furukawa, Director Engineering Technology, Astellas Pharma Inc. (below), presented Astellas’ Tube Labeling Project in Killorglin Co. Kerry, Ireland, which won in the Equipment Innovation category. Astellas delivered a technology innovation allowing it to fill product into common tubes which are printed with only common information for various markets. Then they took their process a step further by adding country specific label information on common tubes.
During Furukawa’s presentation, he touched on the major benefits to the industry from their project. These benefits included:
- Supply chain issues can be dramatically improved through equipment innovation
- For stable production, set design concepts and a quality standard at the early stages and apply throughout the equipment development phase
- Bulk product specs, both known and unknown, should be observed carefully and considered for new equipment design
- New packaging products should be designed and tested with the consideration of how patients will use them
- Flexible communication is vital for a global complex project
Martin Teo, Project Director at AstraZeneca Global Engineering (below), winner of the Project Execution category for their market supply solid dose facility located in Taizhou, China, offered an in-depth look at how AstraZeneca met their ambitious goals. Phase one, of a planned three phase project, consisted of over 533,000 sq. ft. of the total greenfield site development in the new pharmaceutical center of Taizhou. The facility was constructed in a record time of 20 months (ground-breaking to OQ lots complete) at a total project cost of $170M. This AstraZeneca facility is capable of producing 5B tablets in a fully integrated solid dosage site including formulation, tableting, labeling, packing and distribution operations.
Teo described the innovative sourcing strategy that was used to source 95% of the construction materials locally including granulators, fluid bed dryers, tablet presses, coaters and blenders. The benefits of taking the time to source locally materials included:
- Reduced lead times
- Enormous cost savings
- Close proximity to after sales support
At the Membership Breakfast and Awards Ceremony, ISPE announced the 2015 Overall Winner – AstraZeneca China. FOYA Judging Committee, Chair, Jim Breen presented a video highlighting all of the 2015 Category Winners.
Alan Osbourne, Regional Director Asia-Pacific, AstraZeneca China (below), accepted the industry’s most prestigious award on behalf of his team.
AstraZeneca China’s project team (below) impressed the judges with its clear strategic plan. The team incorporated lean design principles to eliminate operational inefficiencies and deliver optimum manufacturing performance. With a 99 percent Active Pharmaceutical Ingredient (API) removal rate from API containing waste water, the facility far exceeded local environmental regulations.
Submissions are in for the 2016 FOYA Awards – stay tuned to find out who will win!