Rottapharm has run over 20 Six Sigma projects over the past five years. Each Six Sigma project carried out within an organisation follows a defined sequence of steps and has quantified financial targets cost reduction and/or profit increase. It uses a set of quality management methods, including statistical methods, and creates a special infrastructure of people within an organisation (Black Belts, Green Belts, etc.) who are experts in these methods. Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects and minimising variability in manufacturing and business processes. In order to improve operations and performance, the Senior Management team at Rottapharm Dublin introduced a Lean Six Sigma program in 2007. Lean Six Sigma and the Operational Excellence programme Volumes of finished product packaged increased significantly, as a result and 35 new positions were created. The project expansion resulted in an addition of four packaging lines, two coating systems and an encapsulation machine. The investment involved the transfer of a number of new processes from another facility within the group. The increase in growth from 2009 onwards was as a result of a seven million Euro investment and facility expansion. Figure 1 shows the growth in terms of percentage output from 2000 to 2012. Production output has grown steadily over the years, with the Dublin site becoming one of the most important manufacturing sites within the Rottapharm|Madaus group of companies. DONA is the first drug of choice to be administered as early as possible in the treatment of osteoarthritis. The company’s leading product DONA, the original Glucosamine Sulphate, is manufactured in sachet and capsule formats for markets in Europe, Asia and South America. The Dublin site employs 150 people manufacturing a range of capsules, sachets and tablet formulations in addition to the API Crystalline Glucosamine Sulphate. The Rottapharm manufacturing site in Dublin, Ireland was officially opened in June 1999 and commenced manufacturing operations later that year. In the pharmaceutical sector, Rottapharm|Madaus has over 13 projects in its pipeline. From the original glucosamine sulphate, an essential molecule in the treatment of osteoarthritis, to pro-glumetacina, a non-steroid anti-inflammatory drug, up to the launching of the first transdermal active matrix patch with estradiol an innovative transdermal releasing system for hormone replacement therapy in the menopause, research has not stopped but in fact has continued to grow and develop in a steady manner. Rottapharm can boast a rich portfolio of original molecules and drugs, discovered and patented by its own R&D department. The field of research is above all the undisputed true mission of the company. After acquiring the German multinational Madaus Pharma in 2007, the Group is currently one of the most significant and prominent pharmaceutical companies in Italy and is present in over 85 countries worldwide. The company from its early beginning has continuously invested in research, innovation and development of pharmaceutical products for distribution on a worldwide scale. From their headquarters based in Monza, Italy, Rottapharm’s long history of success began in 1961 with the creation of a small laboratory for independent research.
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