CAPA for the FDA-Regulated Industry José Rodriguez-Pérez ASQ Quality Press Milwaukee, WisconsinAmerican Society for Quality, Quality Press, Milwaukee, WI 53203, © 2011 by ASQ All rights reserved. Published 2010. Printed in the United States of America. 16 15 14 13 12 11 10 54321 Library of Congress Cataloging-in-Publication Data Rodriguez Pérez, José, 1961- CAPA for the FDA-regulated industry / José Rodriguez. Pérez. pcm. Includes bibliographical references and index. ISBN 978-0-87389-797-6 (hardcover : alk. Paper) 1, Pharmaceutical industry - Government policy - United States. 2. Food industry and trade — Government policy - United States. 3. Total quality management — United States. 1. Title. HD9666.6.R63 2010 615.1068’ 1—dc22 2010031139 No part of this book may be reproduced in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Publisher: William A. Tony Acquisitions Editor: Matt T. Meinholz Project Editor: Paul O'Mara Production Administrator: Randall Benson ASQ Mission: The American Society for Quality advances individual, organizational, and community excellence worldwide through learning, quality improvement, and knowledge exchange. Attention Bookstores, Wholesalers, Schools, and Corporations: ASQ Quality Press books, video, audio, and software are available at quantity discounts with bulk purchases for business, educational, or instructional use. For information, please contact ASQ Quality Press at 800-248-1946, or write to ASQ Quality Press, PO. Box 3005, Milwaukee, WI 53201-3005. To place orders or to request ASQ membership information, call 800-248-1946. Visit our Web site at www.asq.org / quality-press. 9 Printed on acid-free paper Queliy Pres {600 N. Plankivon Avenue Mibwovkee, Wisconsin 53203, Coll ree 800-248-1946 Fax 414-272-1734 5 cna org ASQ Beier og oalnstirsren tp sondern garg mal chonengrgDedication This book is dedicated to my wife Norma and my son José Andrés. Their continuous support and love made this book possible.(This page intentionally left blank)Contents List of Figures and Tables . Preface. Chapter1 The Quality System and CAPA .........006.000005 1.1 The Quality System and CAPA. . 12 CAPA Relationship With Other Quality Subsystems 1.3 Corrective or Preventive?. . ci eeeee eens Chapter 2 CAPA and the Life Sciences Regulated Industry . 2.1 FDA Pharmaceutical CGMP 2.2. FDA Medical Devices QSR. 2.3 FDA Quality System Inspection Technique (QSIT), 1999 . 24 FDA Guidance: Investigating Out-of Specification (00S) Test Results for Pharmaceutical Production, 2006 ...... 2.5 FDA Guidance: Quality Systems Approach to Pharmaceutical Current Good Manufacturing, Practice Regulations, 2006 .... 2.6 European Pharmaceutical GMP (EudraLex Volume 4), 2003 . 2.7 Harmonization Processe: ICH and GHTF . 2.8 ICH Q10: Pharmaceutical Quality System, 2008. 2.9 ISO 13485:2003 and Non-U.S. Medical Devices Regulations. ..........06e0000e08 2.10 GHTF Quality Management System—Medical Devices—Guidance on Corrective Action and Preventive Action and Related QMS Processes, 2009 2.11 Current FDA Regulatory Trends for the CAPA System. .. 21 23 24 25 25 27 28vili_ Contents Chapter 3 Effective CAPA Process: From Problem Detection to Effectiveness Check. . 3.1 Problem Detection: Discovering Problems . 3.1.1 Source of Data About Product and Quality Issues. 3.1.2. Risk Assessment....... 3.1.3 Initial Impact Assessment 3.14 Process Trending 3.2. Problem Investigation: Discovering Root 3.2.1 Symptoms, Causal Factors, and Root Causes ..... 3.2.2. Problem Description 3.2.3. Barrier Analysis .. 32.4 Root Cause Identification Processes and Tools . 3.2.5 Root Cause Categories . 3.2.6 Investigating Human Errors . 33 CAPAPlan: Corrective and Preventive Actions to Fix Root Causes... . 33.1 Establish Effective Corrective and Preventive Actions 3.3.2. Validation and Verification Prior to Implementation. . 333. Implementation of Corrective and Preventive Actions. . 3.4 Effectiveness Evaluation ...... 3.4.1 Verifying That Solutions Worked - 3.4.2. Training Effectiveness... 3.5 Management of the CAPA System 3.5.1 CAPA System Structure . 3.5.2. CAPA Process Metrics. . . Risk Management and the CAPA System . 3.5.4 Management of External CAPA. Chapter4 Documenting CAPA............0seeeeeeeeeeeeeee 4.1 Content of the Investigation Repant/C ‘CAPA Plan. Report. : 4.2 Compliance Writing . 31 33 33 35 42 43 46 47 50 55 56 60 62 76 76 7 78 79 79 80 84 85 85 86 87 89 89 91Contents ix Chapter 5 The Ten Biggest Opportunities of the CAPA System and How to Fix Them. 93 5.1 Timeliness (Lack of) « 98 5.2. Everything is an Isolated Event (Lack of Adequate Trending) . 96 5.3. Root Cause Not Identified . . 98 5.4 Correcting the Symptoms Instead of the Cause .. 99 5.5 Lack of Interim Corrective Actions. . . . 100 56 Root Causes Identified but Not Corrected ..........-.. 100 5.7 Lack of True Preventive Actions 101 5.8 Lack of Effectiveness Verification of the Action Taken... 102 5.9 Multiple CAPA Systems Without Correlation .. . 108 5.10 Abuse of Human Error and Retraining . . 103 Chapter 6 Developing an Internal CAPA Expert Certification... 105 6.1 Content of the Certification ........60...eceeeeeeee eee 105 6.2 Evaluating the Effectiveness of Internal CAPA Training Efforts ........ veeteeeeeeeeeeeaes 109 63 CAPA Certification Exam Example «0.0... ..c.cee 10 Chapter7 CAPA Forms 113 7.1 Event Description and Investigation 14 7.2. CAPA Plan 116 73 Investigation Report and CAPA Assessment Form . 118 74 Human Error Investigation Form.......22....060022.. 122 Chapter8 CAPA Final Recommendations ..........22-0002++ 125 ‘Appendix A ‘Additional Resources bees . . L127 Useful Web Sites... 00... cee ceeeeeeeeeeeeeeeeeeesees 127 Acronyms better eeeetteeeeeees cectveeseeseees 129 Glossary 131 Bibliography ....... bette eeeee becveeeeeseess 137 TNX cece cee ete eect eee eeeneeees 141