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IS THE PHARMA SUPPLY-CHAIN A LOST CAUSE? Hedley Rees Managing Consultant PharmaFlow Ltd.

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Presentation on theme: "IS THE PHARMA SUPPLY-CHAIN A LOST CAUSE? Hedley Rees Managing Consultant PharmaFlow Ltd."— Presentation transcript:

1 IS THE PHARMA SUPPLY-CHAIN A LOST CAUSE? Hedley Rees Managing Consultant PharmaFlow Ltd

2 AGENDA  Why am I so passionate about the Pharma supply chain?  What has been going on in the supply-chain?  How did it get into all this trouble?  Modernization – the route to salvation?  What COULD the future hold?

3 WHY AM I SO PASSIONATE ABOUT THIS SUBJECT?

4 My three phases of enlightenment Life in big Pharma Life in biotech Life as an independent

5 Life in big Pharma  Why did we do it that way?  Why is it so difficult to change anything?  Why the scepticism of modern improvement methods?  What is underneath it all? What is underneath it all?

6 Life in biotech  Why are they starting at the wrong end?.…and who’s doing the sourcing strategy?  Does anyone knows where all the inventory is?....and what condition it is in?  Who is looking after transportation and storage? ….what to you mean ‘I am’!?  They think I’m in charge of shopping too! ….but carry on regardless

7 Life as an independent  All dressed up and nowhere to go…  The Milton Park experience  My glucose buddy  My needle free injection buddy  Accepting the inevitable  Enlightenment reigns

8 Pharma starts at the wrong end…

9 Information, information, information….

10 WHAT HAS BEEN GOING ON IN THE SUPPLY-CHAIN?

11 Pharma as it was, and now is…  1970s  Vertical integration  Local presence in the country market  Mainly small molecule  2010s  innovator, virtual, biotech, generic/bio-similars, speciality Pharma  Biologics  Markets and supply locations globalize

12 The vicious circle of outsourcing Mass outsourcing Rapid expansion of contractor base Rise of Virtual pharma Drives growth in contractors Drive s growth in Virtual Pharma Disconnection Innovations cost ‘real’ money Opportunities for error Price escalation from lock-in Control over lead times Tactical, arms length

13 Dis-integration of the supply chain Outsourcing begins in earnest…..

14 Integrity issues…  Economically motivated adulteration – “Heparin, supplied by Baxter, found to be adulterated, with reports of 574 adverse events and nine patient deaths estimated  J&J/McNeil placed under a ‘Consent Decree’ after numerous recalls associated with supply chain issues.  Novartis shells out hundreds of millions $ in manufacturing issues  Shortages in US/EU supply chains result in governments, patient advocacy and general public searching questions.

15 Security issues…..  Cargo theft and diversion –  “Abbott hit by $4m diagnostics theft in USA” (June 2011)  “Eli Lilly warehouse thieves make off with $76m haul” (March 2011)  Counterfeiting – “Operation Singapore, largest counterfeit operation in EU, where 2 million doses of counterfeit medicine enter UK supply chain in 2006/7”.  “FDA is still concerned that the drug supply is increasingly vulnerable to diversion of legitimate drugs (drugs illegally circulated outside the legal distribution system ie stolen or sold illegally) and concerned about the influx of counterfeit drugs- as both present significant risks to public health”. Rx-360 Newsletter September

16 The fall-out….  Crippling impacts in the areas of patient safety, brand image and reputation, costs of remediation, customer service and investor confidence. A UNIVERSAL CRY FOR CHANGE!  From regulators, governments, other competent authorities and patient advocacy groups.

17 What has been the response?  …EU implements Falsified Medicines Directive.  …EMA consults on dramatic tightening of GDP/GMP  …FDA pens “Pathway to Global Safety and Quality”.  …US Congressional Committees investigate.  …President Obama wades in on drug shortages.  …US Pharmacopeia consults on new Chapter.  …PEW Charitable Trust writes report “After Heparin”.  …GS1 Global Traceability Standard for Healthcare  …FDA Safety and Innovation Act, Title VII

18 HOW DID IT GET INTO ALL THIS TROUBLE?

19 The patent ‘starting pistol’ The starting pistol initiates behaviours aimed at reducing financial impact of failures and preparing for a race to approval Bang!!!

20 The find it, file it, flog it approach…. Eureka! Is it safe? …seems to be Is it active? …seems to be Let’s get into the clinic – FAST! …better make some for tox studies then….

21 Enter the patent fairy… Bye bye my baby Better make a batch for pre-clinical then Hope she realises I’ll be watching her…

22 Making enough for pre-clinical

23 Typical issues emerging… Scarce/bespoke materials specified. Limited sourcing options (starting materials and API) Inappropriate dosage forms. Contractors with insufficient capacity or capability. Poor process yields. Weak compliance with technical agreements. Analytical Methods not adequate. Shipping/storage conditions not adequately defined. Incorrect value declarations to customs. Poor contractor relationships. Channel management not considered. …the list goes on, and on, and….. Severe disconnection between sponsor company and it’s supply chain ‘partners’ due to supply chain neglect.

24 MODERNIZATION – THE ROUTE TO SALVATION?

25 The 21 st Century Initiative  Pharmaceutical cGMP’s for the 21 st Century – A Risk- Based Approach:  Started 2002 and reported late 2004  Desired state: “A maximally efficient, agile, flexible pharmaceutical manufacturing sector without extensive regulatory oversight.” Dr. Janet Woodcock, the U.S. Food and Drug Administration's Deputy Commissioner for Operations

26 Quality by Design (ICH Q8) and PAT  QbD Concepts  Quality should be built in by design  Focus on product knowledge and process understanding  Establishment of design space  Provide opportunities for flexible regulatory approaches  Risk-based regulatory decisions  Real-time quality control and less release testing  Process improvement within design space without further review  Reduction in post-approval submissions  PAT tools facilitates introduction of QbD

27 History of industrial improvement  Industrial Engineering  Total Quality Management (TQM)  World Class Manufacturing (WCM)  Theory of Constraints (ToC)  Lean and 6 sigma  Toyota Production System (TPS)  Systems Thinking  It’s all INDUSTRIAL ENGINEERING!

28 Lean background  NUMMI study, Womack & Jones “The Machine That Changed the World”  Based on Toyota Production System (TPS)  Reduce time between getting order and money in  Respect for people  Continuous improvement  Five principles  Many parallels with TQM, WCM, TOC, etc.  Relate to modernization

29 Five Principles of Lean 1. Specify value from the standpoint of the end customer by product family. 2. Identify all the steps in the value stream for each product family, eliminating whenever possible those steps that do not create value. 3. Make the value-creating steps occur in tight sequence so that the product will flow smoothly toward the customer. 4. As flow is introduced, let customers pull value from the next upstream activity. 5. As value is specified, value streams are identified, wasted steps are removed, and flow and pull are introduced, continue until a state of perfection is reached in which value is created with no waste.

30 Process Village v Value Stream

31 Traditional functional layout– solid dose Key points: Large batches Produce to forecast High in-process inventory Defects are hidden

32 Value stream alignment – solid dose Key points: Schedule pacemaker only. Set rate at TAKT (Production rate required to match rate of consumption in the market place. Pull from the pacemaker (Kanbans and supermarkets) Solve production problems (A3 Management) Take out variation (SPC). Reduce defect rates on incoming materials. Use Single Minute Exchange of Dies (SMED) to reduce cycle time

33 WHAT COULD THE FUTURE HOLD?

34 Overview of a development process Safety Efficacy Quality

35 Principles of Prototyping Design prototype based on full stakeholder involvement, including marketing, manufacturing, procurement, key suppliers Allocate overall management responsibility for the programme Discovery research stays with prototype testing - iterative Focus on manufacturability of compounds using predictive methods Build a deep understanding of material and process capability Institutionalise risk management into development programmes Build an outline of the end-to-end supply chain

36 Principles of Commercial Supply Safety Efficacy Quality GMP/GDP mind-set from the start: Good Supply-chain Practice - GSP Change emphasis from validation to process understanding/capability Place responsibility for defective work on the producers not the quality function Re-define the role of ‘quality’ into improvement activities Deploy PAT Become ‘business process’ oriented and quality systems aware Institutionalise risk management into supply chain

37 Some radical concluding thoughts  Turn the development process on its head – put patient-use first  Don’t award patents for molecules until they are working prototypes  Supply chain for clinic and the market should be under one responsibility - with strong SCM competencies  Teach SCM principles at University to our chemists, pharmacists etc.  The IND/CTA CMC review process should require a higher level of understanding of the compound and it’s manufacturability

38 More radical concluding thoughts  Companies intent on making a financial exit before commercialization should prove the supply chain foundation is sound  Big Pharma should demand supply chain integrity from the companies they do licensing deals with  Regulations won’t solve the issues, and in EU they are likely to make matters worse.  Big Pharma CEO’s must step up to the plate and make change happen – learn from Toyota’s handling of the ‘fo0t pedal’ incident (scientists eventually found no defects in Toyota vehicles and put it down to driver error)

39 Questions?  If there are any further questions, you can get to me in a number of ways: T: +44(0) M: +44(0) E: W: LinkedIn: Book: Supply Chain Management in the Drug Industry: Delivering Patient Value for Pharmaceuticals and Biologics


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