Excellence in execution
In 2021, Aché focused its efforts on the assertiveness of operating costs (GGF), optimization of productive plants (Footprint) and stabilization of distribution activities in our logistics operation, Neolog. There were more than BRL 222.7 million invested in manufacturing facilities, including investments in Pernambuco, modernization of the manufacturing park, acquisition of new equipment and layout improvements in the operational and Quality areas.
We consolidated the maintenance planning of the five factories, harmonizing procedures and efficiently ensuring the operation of our machines, working preventively to ensure the goal of zero breakage. At Footprint, we focus on obtaining the best production direction and start the works at our pilot plant, which will support the development of new products and is expected to be delivered in the first half of 2022.
We also continued the PEO (Operational Excellence Program), which was implemented in 2015 and uses the TPM (Total Performance Management) methodology, providing the necessary support to the areas of operations.
Our performance
We recorded a production volume of 240.7 million units produced in the plants of Anápolis, Guarulhos, Londrina, Pernambuco, São Paulo and third parties and 280.2 million in distributed units. We also had important advances in our performance, reaching 60.3% in our main industrial performance indicator (OEE – Overall Equipment Effectiveness), above the benchmarking of the pharmaceutical market (55%), in the consolidated result of the Guarulhos, Pernambuco and São Paulo plants. In Guarulhos, our main production plant, we also recorded a record OEE, with 62.3% (Solids Manufacturing).
Our productivity, when compared to the main competitors in the BCO Farma (Benchmarking Operational Competitiveness) panel, is 18% above the pharmaceutical market.
Since the implementation of the PEO, we have already obtained an increase of 51.8% in OEE and potential saving of BRL 70.3 million in continuous improvement projects.
Productivity in Pernambuco
At the Pernambuco manufacturing plant, located in the Industrial and Port Complex of Suape, in Cabo de Santo Agostinho, Aché was the first Brazilian pharmaceutical laboratory to bring together all the solutions of industry 4.0 in one place, an initiative that integrates our digital transformation journey. The factory has the ability to communicate with the utilities, logistics and automated warehouse areas. This generation of information and data analysis is what will give us support and agility to the process of continuous improvement. GRI 103-2
We consolidated our solid packaging operation, ensuring production records and we started Phase 2, with the construction of the Solids Manufacturing building and the Quality Control Laboratory. Delivery is expected for the first half of 2022, with the start of production of the first pilot lots in the same year.
We have expanded our ability to store from 3 thousand to more than 16 thousand pallets positions and we started to implement the MES (Manufacturing Execution Systems), system, which should be fully effective in 2023. Its performance will enable the online availability of all data of the batch of a product, including traceability.
Efficiency in Anápolis, Guarulhos, Londrina and São Paulo
Throughout the year, Aché continued to be dedicated to achieving a greater agility in the availability of products, eliminating losses and increasing performance and productivity.
At the São Paulo plant, our major contribution to the business and to Brazil was the production of more than 400,000 Nosint units (723% above the budgeted volume) and more than 291,000 Simbilex units (873% above the budgeted volume), reinforcing our commitment to the health of Brazilians when delivering these drugs, widely used during the Covid-19 pandemic for patients in serious condition.
In Anápolis, we worked on consolidating the operation of our hormone factory and the results of the plant within the Aché group, which also started to rely on the start of PEO activities.
In the manufacture of liquids, in Guarulhos, we set a record in the production of Decongex syrup in August, with a volume produced of 690 thousand units in a single month. In our solids factory, we had the startup of a new tablet coater, the Glatt GC500, bringing more agility in delivery and ensuring expansion of manufacturing capacity. We have also had the installation of a new vial powder filling line, which will support the launch of future products.
At the Londrina plant, due to the pandemic, we suffered from the drop in the volume of antibiotics and the effort was to maintain general manufacturing expenses, with assertiveness in the budget and use of opportunities. In this scenario, we have made manufacturing contracts with third parties, bringing more volume to the plant, helping to dilute costs. The incremental volume is more than 8 million capsules per year.
Logistics and distribution
Labofarma’s distribution process worked to stabilize the operation and ensure excellence in distribution, have agility in billing and reduce distribution costs.
We implemented Reverse Logistics in the drugs segment with the support of Sindusfarma – LogMed Program; in the Cosmetics line, we worked in partnership with Abihpec – Give hand for the future; in the Food Supplements line; and with Abiad – Recupera Program.
In Pernambuco, we obtained an excellent result with the stabilization of the automations that involve the vertical warehouse in less than 60 days, which has already led us to reach 65% of the warehouse’s occupation, guaranteeing the factory’s supply with inputs and Neolog’s supply of finished products without causing any impact on deadlines and performance. Also in Pernambuco, we had the start of operations of AGVs (Automated Guided Vehicle), that handle cargo within the factory without the need for human control, and “transelevators”, which will operate in all movements within the vertical warehouse, storing the products according to systemic parameters and good manufacturing practices.
Product quality and safety
To ensure the quality and effectiveness of our products and ensure the health and safety of consumers, Aché conducts impact assessments on 100% of its portfolio, keeping it in line with current regulatory standards. We use the best manufacturing practices and, in the development stage of new products, research centers carry out studies to evaluate safety and efficacy.
The evaluations occur according to the best clinical practices and in accordance with the international standards of ethics and quality in research. The products made available to the market undergo strict controls and analyzes so that their safety and quality are guaranteed. After marketing, there is monitoring for possible adverse events, in order to mitigate risks that may arise as a result of the use of drugs and products. In 2021 there were no incidents of noncompliance related to safety impacts of our products.
In order to achieve greater alignment and equalization of policies and procedures in all plants of the Company, the structure of the Quality Board underwent review, also resulting in preparation for the challenges that have been imposed by the pharmaceutical market, such as the increasing number of regulations and the expansion of technical requirements.
With the reformulation, Aché’s rigorous Quality System, which follows international criteria and standards, obtained more productivity, a significant increase in operational excellence, greater team engagement and a technical focus to deal with demands in more depth.
The structures of the five factories also gained more cohesion of processes and management, and are aligned and connected to the Company’s strategy, values, and good manufacturing and productivity practices, resulting in the improvement of the systems as a whole.
After we put our products on the market, we have the Pharmacovigilance area, which evaluates and monitors the safety data reported by health professionals and consumers. Periodically, these reports are reported to the National Health Surveillance Agency, according to current legislation. In 2021, we were the first company in Brazil to provide, via WhatsApp, a pharmacovigilance channel for doctors.