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GLOBAL MANUFACTURING AND SUPPLY CHAIN

Lupin takes pride in its quality-led manufacturing base that keeps the customer at the centre of its business philosophy. A global network of state-of-the-art manufacturing facilities has helped us build scale and enabled us to meet customer needs.

Our ability to lead as a global formulations and API powerhouse is an outcome of our unrelenting focus on operational excellence and quality programs. The philosophy is simple – drive continuous improvement and innovation, facilitate teamwork, eliminate efficiencies and encourage lean manufacturing. We are bound by this philosophy across all our 18 manufacturing facilities in India, United States, Japan, Brazil and Mexico.

As per global manufacturing norms, all pharmaceutical facilities are periodically inspected and audited by regulatory authorities like the US FDA, World Health Organization (WHO), MHRA (UK), TGA (Australia), MHLW (Japan), ANVISA (Brazil) and MCC (South Africa), among others. Lupin’s manufacturing facilities are also inspected as a standard practice. Our operations, supply chain and procurement processes are aligned to global commercial plan and protocols. This helps to ensure smooth transfer of inputs into our plants and timely output of products to world-wide customers.

Our Global supply chain has been instrumental in making us the preferred suppliers amongst customers. The key metrics of deliverance like OTIF (On Time in Full) has remained above 95% in majority of the markets. This has enabled improvement in metrics like ‘Forecast Accuracy’, ‘Requirement Vs Commitment’ and ‘Adherence to Plan’ in the current financial year. We value our customers deeply and have placed stringent procurement processes in order to be competitive and serve them on-time. In order to minimize supply dependency, de-risking projects are routinely undertaken for seamless supply and cost optimization.

Highlights for FY 2017

  • Successfully cleared the US FDA inspection at Dabhasa, Indore, Nagpur and Mandideep facilities as well as at the Lupin Bioresearch Centre in Pune during the year.
  • Successful inspections by other regulators such as MHRA (UK), ANVISA (Brazil), PMDA (Japan) and WHO during the year.
  • Quality transformation project was undertaken in collaboration with PricewaterhouseCoopers (PwC) at Tarapur and Goa plant. The learnings from this project are being extended to the other manufacturing facilities as well.
  • New formulations facility at Sikkim commenced commercial production to support the growing market in India. We also expanded our fermentation capacity at Tarapur to support new products – Capreomycin & Kanamycin into our Global Institutional Business portfolio and commissioned pilot Biotech fill-finish dosage formulations facility in Pune.
  • Investing in a new sterile formulations facility at Nagpur, a new Oncology API manufacturing facility at Vishakhapatnam and expanding our OSD facilities at Nagpur & Indore
  • Expansion of our manufacturing footprint overseas by setting up a green-field Oral Solid Dosage (OSD) facility at Tottori, Japan and expansion of manufacturing capacity at its formulations facility in Somerset, US

These investments were made to create sufficient capacities to support future business growth and build new capabilities for complex and specialty generics.

‘DISHA’ – the Company’s initiative for operational excellence completed 5 years. Key highlights:

  • Currently 100+ operational excellence projects are in progress
  • Lupin retained the prestigious QCI-DL Shah National Award for operational excellence for the 3rd consecutive time. We also bagged the 10th Lean Six Sigma National Level Competition organized by CII
  • Lupin continues to live up to high standards set by other global giants like McKinsey & Company on productivity (POBOS- Pharma Operations Benchmarking of Solids)
  • Capability development has always been a key area of focus for ‘DISHA’ – the Company’s initiative for operational excellence. As a result, more than 2,000 Lupinytts have undergone training for Lean, Six Sigma, TPM, MOST and ERR