1. Global EHS Performance FY18
12th July 2018
Pete and Steve Introduction

2. Today…
Pete to present agenda

3. Visitor EHS Instructions Schorndorf
Guy Ridsdill
EHS Manager
2018

4. EHS and Security Instructions for Visitors
At Catalent Schorndorf we are proud of our commitment to Health, Safety and the Environment. Please support us by observing these rules while visiting our site.
Complete clearly and legibly the forms on arrival and departure at reception. If reception is closed when you leave, your guide will contact Security (222).
Please take particular care when crossing the main road between Steinbeisstr. 1 and 2.
Use the marked footpaths and zebra-crossings on the yard.
Everyone entering the Logistics area must wear safety shoes and a hi-visibility vest. Toe-tectors and vest can be provided if necessary.
Beware of pallet-truck traffic in production and logistics - look before you walk!
In case of a fire alarm, your guide will escort you to one of the assembly points.
Smoking is only permitted in the clearly marked smoking areas.
Taking photographs on site is not allowed. Exceptions can be permitted by a member of the Site Management Team. Do not photograph employees without their permission.
If use of mobile phone is necessary, find a safe place and stand still. Don’t walk and talk/text!
Always use handrails on stairs.
Ensure your bags and coat do not cause trip hazards in meeting rooms.
There are First-Aid kits and trained First-Aiders in all departments.
Defibrillators can be found in the hall near the canteen, by the interlock between Production and Packaging and in the reception area of CSS.
Emergency Telephone Nr.: 6112 (external Emergency Services)
We strive to improve our EHS policies and methods continually. If you see room for improvement, please inform your guide.
 We hope you have a successful visit to our site and a safe onward journey.
Roel de Nobel Guy Ridsdill
Managing Director EHS Manager

5. Performance June 2018

6. June Summary

7. FY18 Summary

8. FY18 – Balanced Scorecard

9. BU RIR

10. Global Security & CM-BC Update

11. Incidents/Update – Security & CMBC
Bolton – Travellers on site scavenging in waste bins (x2)
Buenos Aires – Theft of cell phone (*)
Eberbach – Threatening letter (July)
Kansas City – Theft of personal cash (*)
Morrisville – Suspicious individual on site (*)
Swindon – Travellers set up camp on land adjacent to site
Swindon – Accountancy discrepancy on controlled drug
Woodstock – Employee engaged deadbolt to bypass badge reader

12. Incidents/Update – Security & CMBC
Madison – Potential LN2 shortage, due to fire at suppliers
Morrisville – Leak/Flooding in Clinical Manufacturing area (*)
St Petersburg – False fire alarm – service technician performing boiler blow down
Woodstock – EMS system failed due to failure of switch
Woodstock – Power outage (Auto crash damaged utility pole)

13. Performance FY18

14. Our winners
Congratulations to everyone, and thanks for contributing to Catalent’s improving safety performance

15. Work to be done….
Identify actions for improvement, ensure that you have detailed RCA and action plans for all recordable injuries

16. Recordable injuries – root causes
Ergonomics - 28%
Hazard identification and risk assessments - 29%

17. Focus areas for FY19 Risk assessments
Process based RA for tasks not deemed to be “low risk” (HAZOPS approach)
Tracking of Lessons learnt from Recordable Injuries
“Live” audit to track site’s review of applicability of Lessons Learnt
Business level Audits will be more theme based
Deep dives on: Chemical Management, Risk Assessments, Ergonomics
More focus on engagement – CULTURE map, and action plans
New chemical onboarding process
More categorization done in-house
Sites must produce a capability assessment
Environmental monitoring data needs to be collected
We need to monitor how we are performing against our commitment to reduce our environmental footprint
API in waste water (10 focus sites in FY19)

18. Entropy Minimum Reporting Requirements (GM accountability)
Entropy record
Minimum reporting requirements
Level C injury or illness (Recordable injury or illness)
Site (*)
Title (*)
Type of incident (*)
Department where Incident occurred
Organizational Structure (*)
Incident Date (*)
People Involved (Employee who has been injured or suffered work based illness must be loaded – can be “xx.xx” to anonymize).
Injury/Illness
Cause of Injury/Illness
Result of Injury/Illness (only one category to be ticked, relating to the most significant consequence)
Work Related
Lost Time (field to be updated monthly, as necessary)
Restricted Time (field to be updated monthly, as necessary)
Four-blocker, including lessons learnt, to be loaded into Incident Reference, by last day of month in which incident occurred.
(*) Field is identified as mandatory in Entropy
Entropy record
Minimum reporting requirements
Monitoring
Records to be completed on at least a quarterly basis (unless stated):
Electricity usage (Cost)
Electricity usage (Energy)
Gas usage (Cost)
Gas usage (Energy)
ODC losses (Mass) – within 28 days of loss occurring
Waste – hazardous (Cost)
Waste – hazardous (Mass)
Waste – non-hazardous (Cost)
Waste – non- hazardous (Mass)
Sewerage/Discharge (Cost)
Sewerage/Discharge (Volume)
Water usage (Cost)
Water usage (Volume)
Number of Hours Worked – monthly

19. Recordable Injuries Summary

20. Accident: Wrist pain Site: Bathgate
Reference: HSIN3529 Date: 04 Jun 18
Accident Description:
Employee carries out picking activities at weekend within ambient warehouse
A JLG vehicle is used for picking from lower & high level locations within the high density racking aisles
The tray platform on the JLG vehicle is used for stacking the blue corex boxes being picked. No discomfort or issue raised during the work period
Employee returns home early afternoon. Feels a niggle in his wrist later that evening
Employee visits GP the following day and is signed off work from Jun 18
Photographic Record:
Root Causes:
Employee selected the JLG vehicle for picking at lower locations
Corex boxes stacked on the JLG platform via the rear of the JLG
Operator reaching over JLG to place goods on tray
Size of blue corex trays being handled
Corrective & Preventative Actions:
Boxes not to be stacked on JLG from lower locations. Trolley to be used for lower level locations.
Risk assessment for the task to be reviewed to clarify the use of trolleys over a JLG vehicle for lower positioned boxes on high density racking areas.
Cascade risk assessment updates for training awareness
Consider handling characteristics of existing trays and recommend limits on dimensions/weights for good ergonomic handling, and obtain suitable trays to allow these recommendations to be met.
Progress behavioural safety standards phase 2 implementation with respect to education and engagement programme
LESSONS LEARNED POINTS 1
Handling aids used to match the tasks performed 2
Staff awareness of potential issues of a task / behavioral safety

21. Injury Review – Bolton, 26 June 2018 (HSIN4147)
Safety Event Description:
26Jul: A QIP employee was using a (pallet lift) pallet truck and strained/ sprained their arm from the ‘pumping’ action needed to elevate the truck.
Background:
The injured employee was wearing the assigned PPE and performing the task as per SOP.
This is a routine task, carried out many times before.
First aid was given. Employee went the hospital, employees arm placed in a cast, employee diagnosed with Carpal Tunnel Syndrome.
Actions Taken & Next Steps
Correct selection of Electric Pallet Trucks have been obtained from manufactures.
Quotes have been obtained and viewing of the electric pallets trucks to take place this week.
Purchase of the above pallets truck will reduce such incidents from re-occurring in the future due to the removal of pushing, pulling, pumping action required for such activities.
Investigation Details:
Review of the activity Risk assessment and SOP confirmed procedure has been followed correctly and hazards have been correctly identified.
Safe Working Load of the equipment was not exceeded and ruled out as a contributory factor to the incident.
No proof of pre-existing medical conditions present.
It is obvious that using the manual pallet trucks does require substantial force from upper limbs to elevate the Pallet trucks height.
LESSONS LEARNED POINTS 1
Review of SOP, Risk Assessments & SWL of equipment. 2
Purchase modern equipment to reduce hazards and risk.

22. Injury Review – Kansas City (ODD) 8th June 2018
Safety Event Description:
Background:
Employee was working alone in the B3 dissolution laboratory. During this time, the employee was attempting to empty a carboy filled with approximately 38 L of dissolution fluid into a laboratory sink.
 During this process, the employee placed the carboy on a rolling cart which is approximately 10 cm lower than the bench height. The employee then attempted to pour the contents of the carboy while it was still situated on the cart, attempting to use the edge of the bench as leverage.  
Incident:
At this time, the cart began to roll away from the sink and the employee jolted herself while attempting to prevent spillage. Immediately afterwards, the employee began feeling pain in her lower back and decided to terminate her shift at 7:08 AM after notifying her supervisor. The employee did not initially indicate to her supervisor of a potential injury.
EHS Management was not notified until Monday morning when the employee notified her supervisor that she would not be attending work.
Investigation Details:
The ECFA timeline identified the following 4 causal factors: 
Work restrictions not observed by the employee
Employee attempted to drain the carboy via the top (instead of the spigot) while situated on the cart (non-routine task)
Cart used to transport the carboy from the bench to the sink was not level with either the bench or the sink
The employee was a lone worker, subjecting to additional risk.
LESSONS LEARNED POINTS 1
Review of SOP, Risk Assessments & SWL of equipment. 2
Purchase modern equipment to reduce hazards and risk.

23. MAJOR Event Notification:
MAJOR Event Notification: Recordable Injury—Sprain/Strain Site: PHL (HSIN6366) Date of Injury: 23JUN18
Event description:
At approximately 1730 hours on Saturday 23JUN18, Employee reported via text message to Supervisor that she had “rolled her ankle” prior to leaving work at 1330 hours while changing from work boots to street shoes within a toilet stall in the Women’s Locker Room. Employee stated she “didn’t think much of it at the time the Injury occurred” when asked why the report was made four hours after leaving work. Employee was sent to Occupational Health provider on Monday 25JUN18 where she was diagnosed with an Ankle Sprain and fitted with a brace. Although placed on Restricted Duty, we were able to accommodate restriction therefore not losing any work time and limiting any lost time for the employee.
Immediate causes:
Restroom stall is not the appropriate environment to change an employee’s footwear.
The employee did not properly asses the risk with trying to perform this activity in a restroom stall.
The employee was attempting to stand on one foot while slipping work shoe off the other.
The employee was not able to steady herself within the toilet stall having both hands involved in the shoe change.
The employee was not mindful of the need to support herself while putting herself in a position that was not steady.
Corrective and preventative actions:
Immediate confirmation and evaluation made that the locker room area and other areas where footwear may need to be changed, have the appropriate tools (i.e. benches) to perform this activity safely.
The teams will be briefed on the incident, and reinforcement around using the proper equipment or facility to perform specific activities must always be evaluated will be done and all incidents MUST be reported immediately.
Further follow-up with the employee from a job performance standpoint needs to occur due to the her failure to report an Injury at the time it reportedly occurred.
Root causes:
After reviewing surveillance this incident requires additional investigation and evaluation.
A restroom stall that is not properly equipped for changing footwear should not have been used for this activity. There are several adequate benches in the locker room area that are specifically intended for this activity that should have been used.
LESSONS LEARNED POINTS 1
Employees must properly assess the risk of performing any activities or tasks to confirm there is no risk in performing these tasks no matter how minimal it may seem, if there is risk, the employee must action the elimination of this risk which may require other’s support. 2
Reinforce with all Employees the need to report ANY Injury at the time of occurrence, regardless of how one feels at the time it occurs as well as the potential ramifications for failing to do so.

24. Level C: Tendon injury on right thumb Local: Gelatin
Entropy: HSIN6770 Date: 06/26/2018
Photos:
Description occurrence:
After perform the task of scrubbing gelatin of the reactor, the employee closed the equipment and turned on the vacuum and verified that the pressure was not reaching the correct pressure indicated in the BR.
So the employee opened the lid and closed again putting more manual strength in the clamp to have a better seal. Finishing this task, the employee started to fill the production report and felt an acute pain in his right thumb.
He was taken to hospital and referred to a specialist who found an injury on his thumb tendon so he immobilized his thumb and gave 8 days off to the employee.
After the employee finish the task scrubbing the reactor, he closed the cover and started to feel pain in his right thumb.
Actions corrective and preventive:
Review the risk assessment and the SOP of the task to reflect the risks found on the new RA;
Information to all employees about report any issue with equipment prior perform any extra effort during their daily tasks.
Use rubber hammer to open or close the reactor;
Check the reactor components before its use.
Causes:
Difficultness to open and close reactor and use of an extra effort to tighten the screws of lid on this reactor.
The employee first informed that he has injured his thumb after scrubbing, but during the investigation was not found a possible cause during this task.
LESSONS LEARNT 1
Ensure employees are capable to recognize and report any issue prior performing any extra effort /difficultiness on their daily tasks.

25. HSIN–12585 Muscle Strain – Mixing Process Site: Swindon
HSIN–12585 Muscle Strain – Mixing Process Site: Swindon Date of Accident:04-Jun-18
Event Description:
During the mixing process, one of the required tasks is to lift and then close a plunger on the mixer (Pic 1)
This acts as a locating pin for the lid collar (Pic 2) and for removing any residual pressure in the vessel.
This plunger is also released when opening the lid to add excipients or API and can be on average 5 to 10 times during the mixing of one batch.
On this occasion the plunger was difficult to move. This resulted in the IP straining to lift and relocate it, which led to a sharp pain down their left arm.
First aid was provided at the time in the form of an ice pack and the IP was sent home. The following day, after seeing their GP the IP was signed off from work for 10 days.
Pic 1
Pic 2
Pic 2
Root Causes:
The plunger was tight against the locking collar of the mixer, increasing the resistance
The pipework was not aligning correctly and was off centre, creating a natural tension making release difficult
Corrective & Preventative Actions:
Pin diameter has been milled 3mm allowing for greater clearance
Modify existing pipework and install a securing bracket for consistent alignment
Perform a check of all other mixers to confirm if remedial work required
Lessons learnt 1
Machine setup and operational pre checks must be acceptable before commencing with the mixing operation 2
Education of operators on best techniques to move plunger, twist to break any seal tension then lift – do not force

26. Accident: Cut to finger due to sharp edge Site: Windsor, Ontario
Reference: HSIN748 Date: June
Accident Description:
When reinstalling the cover onto the casting drum the operator used extra force to fit the cover and his left finger was cut from a sharp edge that was present on the edge of the cover.
The operator suffered a cut to his left index finger – resulting in stitches to close the wound.
The operator returned to work and no lost time was incurred.
Photographic Record:
Sharp edge
Sharp edge
Root Causes:
Sharp edges present on equipment creating a hazard
Use of extra force when installing the cover
Not getting support from mechanic to investigate difficulty with cover
Lack of risk assessment prior to performing the task
Corrective & Preventative Actions:
Equipment to be repaired and other covers inspected for sharp edges
Awareness training to all operators on the incident and the need for assessment of risk prior to performing tasks
Use of appropriate gloves to be reviewed when installing machine parts
LESSONS LEARNED POINTS 1
Inspection of equipment for potential hazards prior to handling 2
Safety Conscience for all employees – increase awareness to assessing risk prior to performing non-routine tasks

27. discover more.
CATALENT PHARMA SOLUTIONS 14 SCHOOLHOUSE ROAD SOMERSET, NJ
Thank you…
I look forward to meeting and working with you, and in the process, hope to learn a bit more about why you are proud to work for Catalent.

28. Appendix

29. Patient First

30. PATIENT FIRST HEALTH & SAFETY FIRST “PEOPLE FIRST”
Patient First and EHS
PATIENT
FIRST
HEALTH & SAFETY
FIRST
“PEOPLE FIRST”
EHS is critical to our ability to focus on “Patient First”:
It is the same cultural mindset
Compliance
If we are not compliant with all laws and regulations we cannot operate
Understand all the parameters of compliance; from knowing all the processes for our discharges to filing a report
Employee Safety
Less injuries, however minor, ensure that we have our qualified, knowledgeable employees engaged in activities that contribute to our commitment to the millions of people worldwide.

31. SLT

32. Framework for excellence
Hardware
Policies
Procedures
Systems
Metrics
Structure
Training
Software
Communication
Shared values
Accountability
Commitment
Engagement
Skills/Capability
Catalent Confidential – For Internal Use Only

33. Environmental Targets for FY19
Increase in the number of landfill free site to 50% by end of 2020
Catalent has identified the following goals for the reduction of our environmental footprint on a rolling 5 year basis:
Reduce water use by 15%
Reduce wastewater generation by 15%
Reduce waste generation, non-hazardous and hazardous by 15%
Reduce energy consumption and carbon dioxide emissions by 15%
All data should be entered into Entropy on a quarterly basis
Same as FY16.

34. Metrics & Acronyms

35. Acronyms
SC rate per EE – Safety concerns per Employee - Total safety concerns submitted divided by total employees on the site.
SC(EE):SC(Tot) – Safety concerns submitted by employees on their day to day tasks compared
to Safety concerns total.
 SC:R – Safety concerns per Recordable - Total safety concerns submitted divided by number of recordable injuries.
 SC Open/Closure rate – (Total safety concerns - Open safety concerns) divided by total safety concerns.
Incident Open greater than 90 days –Goal is to close all safety concerns in less than 90 days.
 (PSB+SI) per EE – Positive Safety Behavior plus Safety Improvements raised per employee.
 12 month Recordable Rate – Recordable injury rate, this rate is calculated by multiplying the number of recordable injuries by 200,000 and dividing by the number of hours worked. Our goal is to reduce this to zero, however the 2017 fiscal year target is 1.04.
 % change – Change between the last 12 months and the previous 24 to 12 months recordable injury rate.
 OSHA RI in Month – This displays the number of recordable injuries that occurred at the site during the reporting month.
 CAFW in Month – The number of recordable injuries that resulted in loss of a working day or Case Away From Work.
 CAFW:RI – Cases away from work compared to Recordable Injuries

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CATALENT PHARMA SOLUTIONS 14 SCHOOLHOUSE ROAD SOMERSET, NJ 08873