Abbott Cork Case Study - Practical Implementation of ISO...
Transcript of Abbott Cork Case Study - Practical Implementation of ISO...
Abbott Cork Case Study - Practical Implementation of ISO 50001 September 12th, 2012
Presented By: Michael McCarthy CEM
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2 Company Confidential
© 200X Abbott
Background
ABBOTT, CORK
This Site is Located in Cork, About 270 km South
West of Dublin and on the South Coast of Ireland.
Located in the
Pharmaceutical Hub of
Ireland in a Modern “Bulk
Tablet” Finish Facility, Abbott
Ireland Pharmaceutical
Operations in CORK
Manufactures High Quality
Solid and Capsule
Formulations for Worldwide
Distribution
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OVERVIEW
• Wide range of process equipment covering a variety of tableting
formulations
– Granulation, milling, sieving, drying, compression, coating and
encapsulation
• Site utilities include: low pressure hot water, chilled water, steam and
condensate, glycol, compressed air & nitrogen and purified water
systems
• QC laboratory and Warehouse
Laboratories
Warehouse
Plant Room
FACILITY AREA
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Ground Floor Total
Warehouses 1300sqm
Production & Dispensing 3000sqm
Pilot Plant 300sqm
Offices 500sqm
First Floor
Offices 900sqm
Laboratories 800sqm
Plant Room 3500sqm
Miscellaneous 1550sqm
Total 11,850sqm
SITE UTILITIES
• Steam Generation – 3,500 Kg /hr.
• Low Pressure Hot Water – 1750 Kw
• Chilled Water System – 1775 Kw
• Compressed Air System – 1392 Nm3/hr.
• -5 Glycol Process Chiller – 400 Kw
• Purified Water – 11000 Lt/hr. from 2 skids
• Nitrogen Generation – 42 m3/hr.
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8 Company Confidential
© 200X Abbott
System
In the Beginning….
• Conscious of the Potential for Energy Reduction in the Plant, but
in Line with the “Lean” Approach Taken by the Plant, we
Wanted to Ensure That There Was no Unnecessary
Investments Made to Achieve the Savings.
• We Were Also Conscious of the Competitive Pressures Within
the Pharmaceutical Company Space and Needed to Show Our
Ability to Compete in This Cost Competitive World.
• Abbott Recognised the Potential of a Structured Approach to
Energy Management and Consistent with our Approach to Other
Key Areas Decided to Use the Standards Process to Embed the
Energy Savings Culture into the Organisation.
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EHS&E MANAGEMENT SYSTEMS
Cork Holds All 3 EHS&E International Management System
Standards;
– ISO 14001: 2004
– OHSAS 18001: 2007
– ISO 50001: 2011
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Just Another System…..?
• Implementation of ISO 14001 and OHSAS 18001 Achieved in 2009
• Next up – Energy! - Why?
– The Development of EHS Systems and Transition to EHS&E Provided
an Additional Resource and a Deeper Understanding of the Systems
Approach to Energy Management.
– Similar to the ways Quality and Compliance Assists
Operations/Production Activities; EHS&E Would Ensure That Energy
Use, and Management, Would be Directed in a Responsible Manner.
– The Associated Environmental Benefits to Energy Management as well
as the Obvious Technical Competence Available On-site.
– The Overall Audit Experience Had a Positive Reaction; the Team and
Senior Management Experienced the Benefits.
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Just Another System…..? (cont’d)
1. Firstly we Decided to Enhance our Technical Expertise;
– However, Our Initial Foray into EnMS Opened Our Eyes and we Re-
focussed our Efforts on Developing a New System (IS 393)
• Additional Training Followed; CEM and Lead Auditor
2. Partnership Consultant Agreement; (EN 16001)
– We Wanted to Avail of External Expertise and Assistance, However we
Wanted to Retain Local Control, Ownership and Intrinsic Knowledge
– Developed EHS&E Manual, SOPs and Documentation (EN 16001)
– Target Energy Checked Progress and Compliance
– Monthly Meetings (Internal Audits of EnMS) and Milestones/targets
were Scheduled and Adhered to.
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Why Such Aggressive Targets?
From Stage 1 to Stage 2 and EN 16001 Certification - 9 Months
• At Cork we Decided to Continue the Aggressive Standard
Implementation Approach used for ISO and OHSAS;
– We Used Our Stage 1 Audit Report as an Additional Gap Analysis
This Allowed us to Target the Initial NCs by Category and Provide a
Simple Action List Framework; ‘complete the actions, get certified’.
Cork Was One of the first Sites to Gain Accreditation to ISO 50001
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Pillars of EnMS
The Pillars of our Energy Management System are:
• Our Policy
• Our Opportunities Register
• Our Significant Energy Users Register
• Our Action Plan
• Our Energy Review
• Our Practical Approach
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SEUs Register
1. HVAC Motive Power
2. HVAC Chillers
3. Trane Chiller 04
4. Process Glycol Chiller
5. PP01
6. Compressed Air
7. PP05
8. Steam Boiler
9. LPHW Boiler
10. HVAC Thermal
11. Niro and FBD Driers
12. PW Loop
13. Water Meter 2
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• Justification
• Factors affecting usage
• Measured Parameters
• Method of measurement/monitoring
(if appropriate)
• KPI (s) in place
• Level and how often
• Person responsible
• Legal / other requirement
• Significant energy people
• Justification Training / awareness
undertaken
• Benchmark/ reference
• List of opportunities identified
Action Plan
• Item Description
• Source
• Status
• System
• Who's Responsible?
• Responsibility Action
• Target Date
• Means
• Resources Required
• Verification Method
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Process
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Analyse
Past & Present
Energy Use
All sources
within scope
Identify Areas of
Significant
Energy Use
List 1...N
Identify EnPI &
Target Level
Baseline
(Per SEU)
Identify
Op.
control
required
Appropriate
Benchmark?
Metering
requirements
Metering
requirements
Identify
Op.
control
required
Assign
Monitoring &
Report Resp.
Assign
Monitoring &
Report Resp.
Register of
Opportuntiies
(including training)
Responsibility
Means & Timeframe
Verification method
Resources needed
Action Plan
What OFI’s to proceed
Appropriate
Benchmark?
Calibration
Required?
Calibration
Required?
Identify EnPI &
Target Level
Baseline
(Per SEU)
Identify overall
Baseline (per
source)
Appropriate
overall
Benchmark?
(per source)
Identify how to
verify action plan
Savings TargetPrioritise OFI’s
Approve &
Implement
Action Plan
Normalise
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18 Company Confidential
© 200X Abbott
The Results
Energy Performance and Related EnPI’s
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Abbott Cork Have Reduced Consumption of Electricity, Gas and Water by
18%, 17% and 49% Respectively.
The System Delivered Energy Cost Savings in the Order of €500,000
Over This Period With Minimum Capital Investments
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© 200X Abbott
The Future
The Future
• Now That we Understand How Our Energy is Used, We Have
Captured a Plethora of Potential Projects That Will Sustain the
Site and Also Have a Visible Impact on Our Reputation.
• Renewable Energy Projects
– CHP, Biomass
• Optimisation Projects
– ACPH
– Chilled Water & Centralized Chiller
ISO 50001 Will Continue to Drive All Projects On-site and Now
That Everyone Speaks the Same Language; Local and Corporate
Co-operation Has and Will Continue to Become More Efficient
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Thank You!