The workplace ecosystem of the future 24.4.2024 Fabritius_share ii.pdf
Due Diligence Audits
1. www.issehs.com
International Safety Systems, Inc.
Due Diligence Audits at Pharmaceutical
contract Manufacturing Sites in India - Lessons
Learned
Prasanth.K, Deputy Project Manager, India
Pinky Bhatt, Project Manager, Asia-Pacific
International Safety Systems, Inc. (ISS), India
2. AGENDA
Pharmaceutical growth in India
EHS status at Contract Manufacturing
sites
EHS audit objectives and methods
Observations
Outcomes
Lessons Learned
www.issehs.com
4. India – Major focus for Contract
Manufacturing
According to a study in 2013, India is:
4th in the world in terms of production volumes
13th in domestic consumption
Over 55% exports of India are to highly
regulated markets
Largest exporter of formulations in terms of
volume with 14 % market share
www.issehs.com
5. Contract Manufacturing Sites-
EHS Status
Expert in manufacturing APIs and Formulations
Limited EHS resources
– Competent professionals with competency in IH and
Process safety
– Understanding of IH significance especially for high
potent compounds
– Trained mentors such CIHs
Willingness to learn and change
Safety and environmental compliance is little
better – IH Process Safety needs significant
improvements
www.issehs.com
6. EHS Audits
Due Diligence audits for
– Potential suppliers
– With QA/QC Team
EHS Assessments for
– Existing Suppliers
– API Manufacturing sites
– Formulation sites
– Vaccine plant
www.issehs.com
7. EHS Audits Conducted
India:
– Tarapur, Hyderabad, Goa, Mumbai,
Visakhapatanam, Ahmedabad,
Solapur, Cuddalore, Chennai,
Renukoot, more cities
China (Two sites)
Thailand (One site)
Malaysia (One site)
Indonesia (One site)
Egypt (One site)
www.issehs.com
8. EHS Audits Conducted
Germany
– Leverkusen
– Dessau-Wörlitz
Ireland
– Arklow
France
– Calais
Spain
– Barcelona
Ukrain
Hungary (Budapest)
www.issehs.com
9. EHS Audits Conducted
USA
– Rancho Cordova, CA
– North Bend, LA
– Hickok, KS
Canada
– Hamilton
Brazil (two sites)
www.issehs.com
10. EHS Audit Objectives
Evaluate compliance status with local health
safety and environmental regulations
Evaluate site status with Pharmaceutical Supply
Chain Initiative,
http://pharmaceuticalsupplychain.org/
Evaluate site status on generally accepted
industry practices for EHS
www.issehs.com
11. EHS Elements Covered
EHS organization and staffing, Employee EHS training
Air Emissions, Wastewater Management, Waste
Management, Spill Prevention
Hazard Assessment, Risk Assessment and Industrial
Hygiene Program
Process Safety Management
Emergency Response and Planning
Personal Protective equipment -Written programs, Cleaning
and decontamination, Gowning de-gowning
www.issehs.com
12. EHS organization and staffing
EHS Staffing and Competencies
Health, Safety, Environment Policy
Safety committees
Accidents reporting and investigation
Training matrices and training conducted
www.issehs.com
13. Air Emissions, Wastewater Management,
Waste Management, Spill Prevention
License to operate
Permits
Pollution control
Waste water treatment, Water discharge,
sampling, sludge solid handling
Liquid and solid waste handling
Used container, packing material handling and
disposal
Hazardous waste handling and disposal
www.issehs.com
14. Risk Assessment and Controls
Hazard Communication, Chemical Inventory,
Labeling, MSDS
Risk Assessment procedures, Follow up
Qualitative and quantitative exposure assessment
Potent compound handling /Particulate
containment
Hierarchy of exposure control measures and
validation
Equipment and personnel entry and exit
Local Exhaust Ventilation and Preventive
Maintenance
www.issehs.com
15. General Safety and Controls
Job Safety Analysis
Permit Systems
Fall Protection
Machine Guarding
Electrical safety and energy isolation procedures
Housekeeping
www.issehs.com
16. Process Safety
Storage, handling and transportation of
flammable and reactive chemicals
Storage tanks
Pressure vessels
Safety valves
Control of ignition sources (e.g., static
electricity) in flammable area
Inerting, validation of inerting
Compressed gases, boiler and pressure vessels
controls
www.issehs.com
17. Life Safety and Emergency
Response
Means of egress
Fire Protection Systems and Alarms
Written Plans
Evacuation Procedures
www.issehs.com
18. Evaluation Criteria
Parent company specific guidelines
Local regulations
National and international standards
Best Practices in pharmaceutical industries
www.issehs.com
19. Audit Process followed
Planning
– EHS Questionnaire
Site visit (3 to 5 days)
– Opening meeting /introduction
– Walkthrough
– Detailed site visit
– Stake-holders meeting (maintenance, Engineering,
Physician)
– Documents review
– Closing conference
Draft and final report
www.issehs.com
20. Most Common Observations-
Environment
Regulatory
– Environment Consent Requirements (quantity
of waste generated, disposed off)
Non-regulatory
– Determining presence of API in Waste
www.issehs.com
21. Most Common Observations-
Process safety and personal
safety
Process Safety
– Nitrogen inerting not done at all or not validated
– Grounding/Bonding and static electricity control
measures
– Flammable tank/container storage (Dike capacity,
flame arrestor)
Personal Safety
– Energy Isolation procedures
– Fall Protection
www.issehs.com
22. Most Common Observations-
Industrial Hygiene
Qualitative Exposure Assessment
Reliable, reproducible and representative
quantitative exposure assessment for APIs and
solvent
Hierarchy of Controls (RPE reliance)
Robust RPE program
Gowning de-gowning, airlock rooms
Potential contamination of Green Zones
www.issehs.com
23. Outcome
Sites receptive and supportive
Some of the observations addressed immediately
After audits, QLEA and QNEA were conducted with
reliable methods
Containment validation conducted as required from
parent company
Significant increase in awareness for IH and Process
Safety
Basic training conducted
www.issehs.com
24. Lessons Learned
Auditing – especially based on site visit to
determine effectiveness of compliance – is
powerful tool in ensuring EHS compliance status
and reducing EHS risk
Spend more at site at every corner and less in
looking at records
Closing meeting – to receive feedback before
report goes out is critical
Stay away from commenting audit conclusions
such as “show stoppers” until all aspects are
considered
www.issehs.com
India has over 550 manufacturing sites registered with the US Food and Drug Administration, of which 323 are USFDA approved, as on March 2013, says the Indian Commerce Ministry, citing Pharmaceuticals Export Promotion Council of India (Pharmexcil) data. And there are 350 manufacturing sites endorsed by the European Union for their Good Manufacturing Practices in India, as on April 2013, it added.
The EHS Assessments (audits) are mostly conducted along with the QA/QC teams for potential suppliers. The assessments were also carried out for existing suppliers for APIs and formulations including vaccine mfg. plants. Formulations include tablets (coated, uncoated), capsules, liquid orals, ointments, gels