Shruti Bhat PhD, MBA, Operations Excellence Expert
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Valsartan, Irbesartan, Losartan Product Recalls- What are the Lessons for Pharmaceutical Industry?

1/27/2019

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Since September last year, news of *SARTAN drug recalls are doing the rounds. Yesterday's CNN Health carried yet another story on recalls of tainted Valsartan, Irbesartan, Losartan drug products.
Valsartan Irbesartan recalls_ What are the lessons for pharmaceutical Industry
Valsartan, Irbesartan, Losartan product recalls- What are the lessons for Pharmaceutical Industry? 

Straight answer- Big Time Business Process issue which must be rectified ASAP...

And, these 'process issues' are at several areas viz. product development process, manufacturing process, outsourcing or procurement process, customer service process to name a few; though a
company-specific root cause investigation will indicate more business processes that might have fully or partially impacted this drug product recall mess.

Presence of a potential carcinogen impurity in the drug as well as drug product clearly shows flaws in 'development and manufacturing processes'.
Companies that purchased this potentially contaminated API (active pharmaceutical ingredient) obviously have huge flaws with their 'procurement / outsourcing process' and need immediate process re-design!
​
​The fact that, carcinogen-contaminated drug products were consumed by patients show huge issues with 'customer service processes' of pharma companies and pharmacies. The issue with 'customer service process' gets further augmented because of the drug product shortage scenarios patients must now deal with.

As these recalls are not just with native irbesartan, valsartan, losartan products, but also extended to their fixed dose combinations i.e. *sartan combined with other drugs such as amlodipine, hydrochlorothiazide etc., the
product shortage mess gets sticky. Further, since these products are consumed daily, the impact of product shortages on patients (i.e. customers) is more intense...

Related reading:​

Mistake-Proofing Pharmaceutical Products: What can we learn from Valsartan, Losartan and Irbesartan recalls?
Mistake-Proofing Pharmaceutical Product Development, Manufacturing and Logistics, Cost Savings via Poka Yoke
​
Recommended steps to solve this problem:

  1. A logical thing to do in such cases is to study the Value Stream Map and identify all business processes that might have contributed to this mess.
  2. Next take a call on where these 'problematic' processes must be improved or re-designed. You can learn more about business process improvement and redesign here.
  3. Improve or redesign process(es) by using appropriate business improvement methodologies. There are over 18 different business improvement methodologies to choose from. Note that, selection of correct business process improvement methodology is very important too. 
  4. Once the problematic process(es) have been improved or redesigned as the case may be, conduct a robust risk-management exercise with FMEA and install a CAPA.
  5. ​Supplementing CAPA with Error-proofing mechanisms via Poka Yoke highly guarantees a 'no risk' scenario.​​
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​
#Kaizen   #BPM #ContinuousImprovement  #QualityImprovement     #ManufacturingManagement #Pharmaceutical  #LifeSciences #Drugs #FMEA   #RiskManagement  #ErrorProofing #Losartan  #Irbesartan  #Valsartan
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80% Reduction in Product Returns; a Continuous Improvement Case Study: Kaizen-based improvement in Manufacturing and Service Processes

12/13/2018

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Learn how Kaizen was used to improve manufacturing and service processes ...

To learn more about how Shruti can help your organization achieve new heights or to book a Workshop, Contact Dr. Shruti Bhat via Form or WhatsApp
​
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#Lean #ContinuousImprovement #Kaizen  #QualityImprovement  #BusinessProcessManagement  #ServiceIndustry  #ManufacturingManagement #LifeScience  #Food  #Beverage  
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Kaizen Orientation Training

11/18/2018

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Glad to be invited as Course Director and Instructor for Kaizen Courses at Kaizen Leader Academy, Canada
Here are details of fourth course of the series...​​
Kaizen orientation online workshop by Dr Shruti Bhat
​Kaizen Orientation Training Online Workshop is for Professionals at all levels of Management.
 
  • Get answers to everything you wanted to know about Kaizen continuous improvement.
  • Learn in-depth about 9 types of Kaizen viz. Gemba Kaizen, Lean Kaizen, Modular Kaizen, Blitz Kaizen, Flow Kaizen, Process Kaizen, Personal Kaizen, Daily Kaizen, Agile Kaizen and how each Kaizen type can help you achieve success with your Kaizen initiatives.

The workshop has 2 Modules of self-paced study, training videos and instructor support. The workshop also includes 3 Case Studies of successful Kaizen implementation.

Participants must complete Tests (open-book exam) associated with each study module; successful participants get a Certificate of Completion- Kaizen Orientation online workshop.

After successful completion of the workshop, participants gain the knowledge to apply Kaizen in their organization.

#Kaizen

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Kaizen Champion Certification Online Course

11/15/2018

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Glad to be invited as Course Director and Instructor for Kaizen Courses at Kaizen Leader Academy, Canada
Here are details of third course of the series...

Kaizen Champion Certification
kaizen champion certification online course, kaizen training

Kaizen Champion Certification Online Course is for Professionals at all levels of Management.

  • Learn how to select Kaizen projects, strategize, design and implement Kaizen continuous improvement campaigns.
  • Lean how to drive Kaizen projects successfully, create profits, reduce defects- overheads- errors, increase productivity- sales-market share- customer satisfaction. Take your company and career to the next level!
  • Learn in-depth about 9 types of Kaizen viz. Gemba Kaizen, Lean Kaizen, Modular Kaizen, Blitz Kaizen, Flow Kaizen, Process Kaizen, Personal Kaizen, Daily Kaizen, Agile Kaizen and how each Kaizen type can help you achieve success with your Kaizen initiatives.
  • The course has 6 Modules of self-paced study, training videos and instructor support, a Toolkit comprising 52 tools and 5 Case Studies that help you apply Kaizen to your organization.
  • The course includes videos showing real-time application of Kaizen in 5 reputed companies in US and Japan.

Participants must complete Tests and Assignments associated with each Module. All tests and assignments are open book exams. Kaizen Champion Certificate shall be sent to participants once they complete all tests and assignments successfully.

After successful completion of the course, participants gain the vision, knowledge and capacity to drive Kaizen implementation in their organization.

​
#Kaizen #KaizenChampion #KaizenCertification 

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Kaizen Certification Masterclass For Pharmaceutical and Medical Device Companies Online Workshop

11/9/2018

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Glad to be invited as Course Director and Instructor for Kaizen Courses at Kaizen Leader Academy, Canada
Here are details of first online workshop of the series...

Kaizen Leader Masterclass for Professionals from Pharmaceuticals and Medical Device Companies.​
Kaizen leader masterclass for pharmaceutical and medical device companies workshop by Dr Shruti Bhat
Kaizen Leader Certification Masterclass Online Workshop is for Leaders and Professionals at all levels of Management in Pharmaceutical, Medical Device and other Life Sciences Industry.
 
  • Learn how to be a Kaizen Leader. How to select Kaizen projects, strategize, design and implement Kaizen campaigns.
  • Learn how to set up a Kaizen Continuous Improvement department at your workplace.
  • Lean how to drive Kaizen projects successfully, create profits, reduce defects- overheads- errors, increase productivity- sales-market share- customer satisfaction. Take your company and career to the next level!
  • Learn in-depth about 9 types of Kaizen viz. Gemba Kaizen, Lean Kaizen, Modular Kaizen, Blitz Kaizen, Flow Kaizen, Process Kaizen, Personal Kaizen, Daily Kaizen, Agile Kaizen and how each Kaizen type can help you achieve success with your Kaizen initiatives. ​
The workshop has 7 Modules of training videos and instructor support, a Toolkit comprising 52 tools and 30 Kaizen templates, that help you apply Kaizen to your organization. 

The workshop also includes 7 Case Studies of successful Kaizen implementation and includes videos showing real-time application of Kaizen in 5 reputed companies in US and Japan.

Participants must complete Tests and Assignments (open-book exam) associated with each study module; successful participants get a Kaizen Leader Certificate.

After successful completion of the course, participants gain the vision, knowledge and capacity to design Kaizen strategy and lead Kaizen implementation in their organization.

#Kaizen #KaizenLeader #KaizenForPharmaceuticals #KaizenCertification ​

    Contact Registration Office for Brochure

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Workshops, Seminars & Online Course on Continuous Improvement by Dr. Shruti Bhat

11/6/2018

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​#ContinuousImprovement #Kaizen #Workshops  #ServiceIndustry  #ManufacturingManagement  #LeanInnovation  #Pharmaceutical  #LifeSciences  #Food  #Beverage  #Biotechnology  #Retail  #Cosmetics  #PersonalProducts  #Chemicals  #Drugs #Engineering #BPM  #LeanManagement  #KaizenLeaderMasterclass  #LeanSixSigma  
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Mistake-Proofing Pharmaceutical Products: What can we learn from Valsartan, Losartan and Irbesartan recalls?

11/3/2018

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First Valsartan, now Irbesartan formulations are going thru a recall. As these product recalls are happening world-over, the chaos is enormous...
Mistake proofing pharmaceutical products_ what can we learn from valsartan losartan and irbesartan product recalls
For the affected patients, it is horrifying to learn that they have unsuspectingly consumed a medicine that contains a potential carcinogen. In addition they have now to deal with product shortages; a product they consume daily to keep their blood pressure in check!

For pharma companies, this is a huge hit to their brand image as well as to their bottom-line. 

Even though Impurities in drugs and drug products are a part of manufacturing process, drug companies strive hard to keep them at minimal and within specifications; be it as per ICH, FDA or company's internal standards. So what happened in case of Valsartan, Irbesartan? Are compendial testing procedures adequate? How were these impurities missed?

Several such questions arise... A root cause analysis will dig into reasons for the lapse, but prevention is better than cure … this is more so true for defective pharmaceutical products. Lesson learnt from *SARTAN mishaps is as a wakeup call !

Recalls will surely stop patients from taking defective batches of Valsartan, Irbesartan. But what about the damage already done to patients who have consumed these defective products? And what is it that we must do to prevent something similar from happening again; not only for *SARTANs but any other drug or drug product?
​

Impurities in drug/drug products: How NOT to miss them?

Pharma R&Ds follow rigorous procedures to keep impurities/ degradation products at minimal possible levels. Drugs and drug products are developed using high standards and elaborate regulated procedures, yet how were these impurities missed out? And what to do to NOT miss them?
A thumb rule whenever a 'defect' occurs means, underlying 'processes' are faulty and must be revisited- improved or re-designed. 

Here's the starting point-

Drug and drug products are developed using ICH Quality norms, QbD (Quality-by-Design), PAT (Process Analytical Techniques) and similar such sophisticated guidances which facilitate 'risk-assessment'. Based on *SARTAN scenario, a logical question that pops up is- Are these 'risk- assessment' tools good enough? Or is there an application failure? In the former case, guidance documents need overhaul, while the later, points to inadequate training (around appropriate implementation of these guidances).​
Secondly, the whole concept of 'Mistake-Proofing' pharmaceutical products must be revisited ...
​Impurities are consequence of drug/ drug product manufacturing process. Any potential carcinogenic impurity carry overs into medicinal products and patients is no doubt hazardous; but it doesn't end there. What about these carcinogenic impurities getting into effluent systems and perhaps into the environment? This puts a larger population at risk!

Existing IPQC, QA monitoring norms are not good enough when we deal with complex small molecule drug candidates. All processes (technical and/or operational) leading to the products must be studied comprehensively,  supervised, modified and improved 'Continuously' ...
A comprehensive Continuous Improvement methodology such as Kaizen must be rooted into pharmaceutical company operations 
Thirdly, stronger risk-assessment and risk-control tools must be adopted during development and processing of pharmaceutical products. Additionally, multiple risk-assessment and risk-control tools must be employed as standard operating procedure.

​Besides CAPA, FMEA, QbD, ICH and compendial norms, a structured 'Mistake-Proofing' methodology such as Poka Yoke- a Japanese concept for 'Mistake-Proofing', must be adopted as an integral part of Drug Discovery and Drug Product Development programs.​
Poka Yoke based Mistake-Proofing must be customized by companies for their line of business and product mix.
Practicing such 'Mistake-Proofing-by-Design' principle will imbue pharmaceutical products with quality to face any rainy day. It main rain tomorrow!

You may also like:

Mistake-Proofing Pharmaceutical Product Development, Manufacturing and Logistics, Cost Savings via Poka Yoke
Book on Kaizen for Pharmaceutical, Medical Device and Biotech Industries; released as Paperback and Digital editions!
Improved Productivity of Pellet Manufacturing: 28% rise in output per shift: Continuous Improvement Case Study
Follow Shruti on Twitter, YouTube, LinkedIn 

#Manufacturing #Lean #ContinuousImprovement #Kaizen  #QualityImprovement  #Losartan #Valsartan #Irbesartan #USFDA   #Quality  #eLearning  #ManufacturingManagement #Pharmaceutical  #LifeSciences   #LeanManagement  #KaizenMasterclass    #RiskManagement  #Impurities
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