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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20 Company Confidential

© 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!