Professional Documents
Culture Documents
GPL SMF 2010 PDF
GPL SMF 2010 PDF
DOCUMENT NO.
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INDEX
SL. No.
TITLE
PAGE NO.
1.
INDEX
2.
APPROVAL SHEET
C.1
GENERAL INFORMATION
3 TO 15
C.2
PERSONNEL
15 TO 18
C.3
18 TO 34
C.4
DOCUMENTATION
35 TO 36
C.5
PRODUCTION
37 TO 44
C.6
QUALITY CONTROL
45 TO 46
C.7
C.9
C.10
CHANGE HISTORY
C.8
47
47 TO 49
50
51
SL. NO.
ANNEXURE
PARTICULARS
01
ANNEXURE I
Photocopy of Manufacturing
Licence
02
ANNEXURE II
ANNEXURE III
Layouts detailing
men/material movement,
General Layout and AHU
Classifications,
03
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Sl.
No.
ACTIVITY
DEPARTMENT
1.
Prepared By
Mr. HARIPRASAD.S
(Junior Officer QA &
Regulatory)
Quality
Assurance
2.
Checked By
Production
3.
Checked By
Quality Control
4.
Approved By
Quality
Assurance
5.
Authorized By
Dr. B.S.MAHADEV
(Director Technical & Works)
Overall InCharge
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Group Pharmaceuticals Limited was founded in 1980, It is engaged in manufacturing and marketing of
Liquid (Oral, Syrups, suspensions, mouthwashes), External Preparations and cosmetics across the globe.
Group Pharmaceuticals Limited strives to provide high quality pharmaceuticals that improve the health of
the customers. A team of personnel of various disciplines and pharmacists are working towards to meet the
customers requirements and the objective of continuous improvement in quality.
Group Pharmaceuticals Limited has complimentary production facilities, good marketing network and
foreign collaborations too. The company has geared up to march ahead in facilitating its consumers with all
the latest developments that has taken place in the pharma market with regards to Oral care healthcare and
other pharmaceutical products.
This Site master file is related to GPL, dedicated to manufacturing of External Preparations (Creams,
Ointments, Pastes, Gels, Lotions, Solutions) and Liquid (Oral, Syrups, suspensions, mouthwashes)
Preparation, located at Plot No. 41, KIADB Industrial Area, Malur- Kolar District 563 130
Karnataka, INDIA; which is about 53 km from Bangalore City and 20 KM from Hoskote and the nearest
railway station is at Malur which is 1.5 km away from manufacturing plant.
C.1.2 LICENSABLE ACTIVITIES
This site is licensed to manufacture pharmaceutical products under the own manufacturing license number
KTK/25/475/2001, KTK/28/339/2003, and KTK/32/268/2006 issued by Drugs Control Department,
Government of Karnataka, India.
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Karnataka, INDIA
Phone:
+91-(0)-8151-234237
Fax:
+91-(0)-8151-235084
+91-0-2525-272108
Fax:
+91-0-2525-274036
IV Floor, S.V.Road
Goregaon west, Mumbai-62
INDIA
Mobile No.
+91-(0) 080-23376766
+91-(0) 9342838923
+91-(0) 8151-235220/234237
+91-(0) 9343661007
Mr. A.T.Rao
Sr. Manager Production
atrao@grouppharma.in
+91-(0) 8151-235220/234237
+91-(0) 9342245271
+91-(0) 8151-235220/234237
+91-(0) 9359889460
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B) Fire Station :
= 4 acres
Built up area
Age of Building
Type of Building
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Section Module I
Area
( m2)
01
Manufacturing Area
47.4
02
18.4
03
5.8
TOTAL
71.6 m2
Sr.
No.
Section Module II
Area
( m2)
01
Manufacturing Area
40.1
02
20.3
03
34.3
04
20.2
TOTAL
114.9 m2
Sr.
No.
Area
( m2)
01
Packing Area
77.9
TOTAL
77.9 m2
Sr.
No.
Area
( m2)
01
Manufacturing Area
46.3
02
24.8
04
21.8
TOTAL
92.9 m2
Sr.
No.
Area
( m2)
01
Packing Area
70.8
TOTAL
70.8 m2
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CATEGORY
Technical
NUMBER OF EMPLOYEES
14
Production-Manufacturing
Non-Technical
Technical
20
Non-Technical
06
Technical
11
Non-Technical
01
Technical
09
Non-Technical
19
Technical
06
Non-Technical
09
Supervisor
01
Labourer
29
Quality Control
Quality Assurance
Engineering
House Keeping
Administration
--
12
Security
--
12
Technical
61
TOTAL EMPLOYEES
Non-Technical
316
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PARTY NAME
01.
02.
03.
04.
05.
06.
07.
Cipla Limited
08.
09.
10.
Medopharm
11.
12.
13.
Pharmed
14.
15.
Zentiva Healthcare
16.
Eminent
17.
Juggat Pharma
18.
Sunways
19.
Grandix
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Sl.
No
01.
Tel
No.
Phone:
080 23388895
Fax:
080 23385979
Phone:
080 5353961
02.
03.
Fax:
Phone:
040 23734720
04.
Ameerpet, Hyderabad-560038
Fax:
Phone:
040 3406557
05.
06.
Fax:
Phone:
042-26585811,
Fax:
26585855
Phone:
91-22-25786466,
07.
25798330
Mumbai-400083
Fax:
Phone:
28699888,28602292,
28683666
Fax:
28602297
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Sl.
No
08.
Tel
No.
Chemi Labs
Phone:
040-23073496
Phone:
080-3343376, 3340395
Fax:
080-3340395
th
Phone:
91-080-26679604
Fax:
91-080-26614101
Mobile
98455 97918
Pesterad Services
st
Phone:
91-080-26530093
Tele-Fax:
91-080-26654488
Mobile
9845046294
Phone:
91-080-22243411
Tele-Fax:
91-080-22243412
G. SHANKAR RAO
Phone:
91-080-26693694
MAHALASA KUTIR
Tele-Fax:
91-080-26693693
Mobile:
9845289612
ACVS
Calibration Services of Electrical, Mechanical &
Control Instruments Kyaswar mansion, No.: 180/44, 16
th
th
Bangalore-560 022.
3.
5.
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Phone:
91-44-42233200
Fax:
91-44-28202327
Phone:
91-080-26586647
Mobile:
9844113826
Phone:
91-080-42043737
LTD
Tele-Fax:
91-080-25203035
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QUALITY POLICY
To provide consistently high quality oral health care and other pharmaceutical products to the
satisfaction of the medical profession and the consumers.
This is being achieved by cumulative efforts from the top management to the lowest cadre of the
workmen by maintaining pre set workman standards aimed at defect prevention rather than
defect detection.
Hence we at Group Pharmaceuticals Limited are totally committed to meet fully the quality and
other requirements. Also we are committed to continually improve the effectiveness of the
Quality Management System.
Managing Director.
Responsibilities of the Quality Assurance Department
Dated:
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about 14 years of professional experience in the responsible area. Site Sr. Asst. Manager QA and Executive
RA reports to Head Quality.
The following flow diagram represents the organizational structure of Quality Assurance function in the
Company.
There are approved standard operating procedures for each and every activity carried out at the site.
Implementation of these procedures is the responsibility of the user, which is also monitored by a team of
trained Quality Assurance officers. General Manager QA approves all the procedures, protocols and
reports. For each product, in-process specifications, finished product specifications, analytical procedures
and limits are defined and checked by General Manager QA. Approved specifications for Raw Materials
and Packaging Materials are also available to control the quality of inputs going into the products.
Release of a batch not only depends on the conformance of the intermediates/ finished products to the
standard specifications, but also on the review of the Batch Manufacturing Record, Batch Packing Record
and analytical reports by Quality Assurance Department. QA Department authorizes the release of the
product for sale/ distribution.
Audit programmes
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Self inspections are conducted at the site at defined intervals. Besides self inspections, external audits by
regulatory authorities are carried out as per requirements. The audit reports and the compliance report are
documented by the site Quality Assurance.
We follow National and International cGMP guidelines to audit the Quality Assurance systems within the
company and the same approach is extended to our vendor qualification as well.
The assessment of Vendors
A documented procedure is available for the assessment, evaluation and approval of vendors. All materials
used at the site are obtained from APPROVED VENDORS only. Vendors supplying materials are
audited as per the schedule and on need basis. QA shall evaluate the performance of the vendor.
C.2 PERSONNEL
C.2.1 Organisation Chart
Quality Assurance(QA) and Quality Control(QC) Function is independent of all other plant functions. Head
QA reports to Managing Director. All other GPL functional departments reports to Director works.
C.2.2 Qualifications, Experience and Designation of Key Personnel
Academic
Qualification
Experience
M.Sc, Ph.D in
Microbiology
26 years
B.Pharma
14 years
GM Corporate QA & RA
Ph.D in
Chemistry
35 years
GM Corporate QC
Mr. A.T.Rao
B.Pharma.
15 years
M.Sc
11 years
Name
Dr.B.S.Mahadev
Designation
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PLANT ORGANOGRAM
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C.2.3 Training
Training has been identified as the key area for updating the skills and cGMP knowledge of personnel
engaged in various activities at the site. We have an Induction Manual, approved Training SOPs, which
provide required guidelines for induction and training of employees at the site. Training needs are identified
by the department managers. Based on the identified training needs and the annual training schedule on
SOPs and cGMPs, training sessions are conducted by qualified trainers of the organization and/or through
expertise from external agencies. Training Evaluation is done through questionnaires as applicable.
Training records are compiled in the individual training files of employees by HR in coordination with QA.
Training records include attendance sheet, answers to questionnaires, evaluation and trainers comments.
Based on Trainers assessment, re-training needs are identified.
A qualified and experienced consulting medical specialist, appointed by the organization is responsible for
checking the health of the employees.
All employees have to undergo a pre-employment medical check-up to demonstrate that they are healthy
and free from contagious diseases.
All employees are medically checked annually and their state of health reviewed. On recommendation by
the doctor, corrective action is taken for the employee concerned. For employees engaged in visual
checks/colour checks/ packaging performance checks (e.g. Quality Control Chemists), the routine check
also includes eye testing.
All employees are advised to report any sickness, including sickness of their family members.
All
employees reporting sickness have to produce a fitness certificate before being allowed to work in specified
areas such as Production, Engineering, Stores, Quality Control and Quality Assurance.
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Personnel entering the production area have to undergo primary and secondary change in the respective
change rooms, as per defined entry and exit procedures.
Primary change is the change from street clothing and footwear to factory uniform and footwear.
Secondary change involves wearing of protective clothing and change of footwear. Persons who are in
direct contact with the product will undergo the secondary change uniform of respective modules to ensure
high level of work comfort.
There is an approved procedure for gowning and de-gowning procedures. A dedicated bin for collection of
used linen is provided.
The Plant has been provided with change rooms and hand wash facilities. Employees are trained in the
gowning procedures, which are displayed in the change rooms.
Employees are also trained in hygiene aspects, which are regularly monitored by production supervisors
and QA Officers. Photographs displaying gowning procedure are also displayed in the change rooms
General Layout of the premises and equipment are enclosed. Annexure- III
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MANUFACTURING BLOCK:
The core production area, warehouse (includes raw & packaging materials & finished goods area) & water
system in the ground floor; utilities (AHU and chiller) in the first floor.
The foundation of the facility has been given anti termite treatment. The terrace has been treated with
waterproof compounds. The periphery of building is constructed of brick walls, cement masonry and
reinforced concrete cement (RCC) roof. The flooring of the manufacturing areas, primary & secondary
packing areas and the corridors are coated with non-shrinking hard coatings of resin (epoxy resin). Wall to
floor and wall to ceiling covings ensure easy cleaning of GMP area.
The corridors are designed to enhance viewing of the manufacturing operations without physically entering
the processing areas. All doors and the windows are flushed to the wall and have a smooth finish. Each
processing area is provided with an independent flush door. All entrance points to the facility have list of
authorized entry of personnel.
There are separate storage areas for raw materials, packing materials, printed packaging materials and
finished goods. UPS system provides lighting in the Manufacturing and Packing Area during power
failures. All the ducting, electrical lines and utility lines are either taken above the false ceiling or concealed
within the wall. All the luminaries are flushed with the ceiling and electrical control panels and the switches
are flushed with the wall.
PACKAGING AREAS:
Construction and finishing of primary packaging areas is similar to process areas. The roof is of RCC and
Floor is epoxy coated. Entry to secondary packaging and manufacturing areas are separate. Primary and
Secondary packaging areas are separated from each other.
WAREHOUSE:
Construction and finishing of warehouse areas is similar to process areas. The roof is of RCC and Floor is
epoxy coated. Doors are made-up of aluminium. Security to warehouse is ensured by providing iron
shutters at the entry point. An unloading bay in warehouse is made for ease of loading & unloading
activities.
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Technical
specifications
Type
Re-circulation
Quality of air
Temperature
Between 25C + 2C
Relative
humidity
No. of air
changes
Pressure
differential
Filter
Configuration
NMT 30C
Efficiency
90%
99.5%
99.97%
All three module have independent air handling units to achieve required temperature and air quality
standards of class 1,00,000. Exhaust systems are fitted with 20 filters on discharge side for ventilation
system. Manufacturing, filling and sealing area is provided with temperature and humidity control system,
other area has only temperature control, terminal filters are provided only in necessary areas. Service floor
is provided in the building on the first floor level for AHUs and ducts are above the false ceiling.
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A schematic diagram of the De-mineralised water system, which is an ion-exchange type is given below.
Purified water is at ambient temperature.
Water is sourced from bore well and is stored in under ground raw water storage tank. This raw water is
used for domestic purposes and as input for the DM water plant. The capacity of the de-mineralised
water plant is 2 KL per regeneration.
A loop system is provided for the distribution of purified water. Distribution supply lines are made of
Stainless Steel 316 material.
a) Pre-treatment of water.
Raw/ Portable water is passed through Sand filter to filter the foreign particles followed by
chlorination.
b) DM- unit
Pre-treated water is passed through activated carbon filter to remove the chlorine content, then
water is passed through Cation bed, Anion bed, Mixed bed followed by 5, 1 cartridge filter
and UV light. Finally purified water is collected in two storage tanks (Stainless Steel 316
tank) of capacity 4,500 Ltrs. Each.
c) Distribution system
Circulated in loops to all the user points.
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Chlori
nation
WATER FROM
BORE WELL
D.M.PLANT
TOILETS
25,000 LITERS
STORAGE TANK
25,000 LITERS
STORAGE TANK
KITCHEN
QC
Water is sourced from bore well and is stored in under ground storage tank of capacity 25,000 Liters. This
raw water is passed through sand filter followed by chlorination and stored in under ground storage tank of
capacity 25,000 Liters which is used for domestic purposes and as input for the DM water plant. Raw
water is supplied through a GI pipe.
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a)
DOCUMENT NO.
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Potable/Raw water direct from bore well is tested at the sampling points with the following
frequency:
Sampling
Point No.
S1
Details
Raw water sampling point before Chlorination
Types of water
Frequency
Sampling
Potable Water
Monthly Twice
b)
S2
Potable Water
S3
Potable Water
Weekly Once
S4
Purified water
Weekly Once
Purified water sampling points and their testing frequencies are as follows.
Details
Types of water
S5
Purified
S6
Purified
S7
Purified
S8
Purified
S9
Purified
S10
Purified
S11
Purified
S12
Purified
S13
Purified
S14
After UV Light
Purified
Frequency
Sampling
Daily
Daily One
User Point.
Weekly Once
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SPECIFICATIONS
Description
Turbidity
Should be absent
pH
Hardness
For Information
MICROBIAL CONTAMINATION
TESTS
ACCEPTANCE
CRITERIA
SPECIFICATIONS
CFU / ml
(ii) Test for specified organism
(a) Escherichia coli.
Absent
Absent
Absent
(d) Salmonella
Absent
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SPECIFICATION
Description
Conductivity at 25c
NMT 4.3 S cm -1
pH
Ammonium
Chlorides
Nitrates
Sulphates
Residue on evaporation
Acidity or alkalinity
Should comply
Oxidisable Substance
MICROBIAL CONTAMINATION
TESTS
ACCEPTANCE CRITERIA
SPECIFICATIONS
Absent/ml
Absent/ml
Absent/ml
(d) Salmonella
Absent/ml
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The pre-filters are dismantled and cleaned using vacuum cleaners. The filters are then washed using a
soft nylon brush. The filters are allowed to dry, and after drying the integrity of the filters is checked by
visual inspection. The filters are then put in the system.
The frequency of filter cleaning is: - weekly once
5-micron/10-micron filters: as per approved schedule and if any incident of pressure differential crossed
beyond the standard limits.
HEPA filters shall be replaced if any damages or incidents of pressure differential crossed beyond the
standard limits. Annual filter integrity test (non-viable count) is conducted at least once a year or as on
need basis.
Purified Water loop is sanitized at a predefined frequency schedule by circulating hot de-mineralised
water & Passivation is done every year. There are approved procedures for cleaning of air handling units
and water systems. Log books are maintained for cleaning activities.
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The production department has all the required equipments/ machinery to carry out the activities of batch
manufacturing and packing. All equipments are cGMP compliant. Product Contact parts are made of
Stainless Steel 316. It is also ensured that, equipment design facilitates easy cleaning and operation.
Equipment details
1.
2.
3.
4.
5.
6.
Filter Press
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Overprinting machine
18.
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Sl. No.
Equipment details
1.
Incubators
2.
Autoclave
3.
Microscope
4.
5.
Colony counter
6.
Refrigerators
Equipment details
1.
2.
UV Visible spectrophotometer
3.
K.F. Titrator
4.
Weighing Balance
5.
Potentiometer
6.
UV Chamber
7.
Polarimeter
8.
pH- meter
9.
10.
Conductivity Meter
11.
Fume Cupboard
12.
Refractometer
13.
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In order to ensure that all equipments and machines perform effectively, planned preventive maintenance
is carried out by the site Engineering Department.
Detailed procedures for preventive maintenance are available, which define the frequency of preventive
maintenance. The procedure includes a preventive maintenance checklist for each and every equipment/
machine.
If any equipment/ machine is not available for preventive maintenance, or preventive maintenance cannot
be carried out for some reason or the other, an alternate date is scheduled and authorised by the
Production personnel in coordination with engineering & QA.
Few equipments/ machines are serviced by external agencies at agreed frequencies. Laboratory
equipments are put under annual service contract with outside agencies.
Records of preventive maintenance by the external agencies are also maintained and reviewed by QA
Manager or his authorized QA person.
If any equipment/ machine needs servicing, the operator of the equipment reports to the department
manager through his supervisor. A request for service is then forwarded to the Engineering Department
with details of the service required and the date on which the servicing of the equipment can be done.
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Companys validation plan and philosophy is defined in Validation Master Plan of the site.
The approach is to establish consistency in product quality through validated processes, using qualified
equipments in a facility that has been qualified to meet the designed specifications with respect to area
and environment. This is backed up by using validated support services and analytical methods.
Before any validation exercise begins, protocol is prepared, checked and approved. Validation is
performed and then reports are compiled, evaluated. Conclusion is drawn, which is reviewed by
designated technical heads and finally signed off with comments and remarks.
Index, Objective, Scope, Responsibility, Validation team, Procedure, Acceptance criteria, Revalidation
Criteria, Data generation as per protocol, Data Compilation and Evaluation, Summary, Conclusion,
Approval of Conclusion.
EQUIPMENT QUALIFICATION
Equipments are subjected to DQ, IQ, OQ & PQ as per pre-approved protocols. Operating, cleaning &
maintenance procedures are written down and approved. Maintenance schedules are defined. Critical
Instruments attached to equipment are calibrated. Vendor of the equipment becomes a part of validation
team. Validation reports are reviewed and concluded and finally signed off.
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PROCESS VALIDATION
First three consecutive batches of each product shall be validated to ensure that the manufacturing
process consistently produces the product to meet the pre-determined specifications. Any change,
thereafter is through change control approval. If the change asks for revalidation of process, the same is
again carried out. Validation activities shall be executed through approved protocols and SOPs shall be
strictly adhered. SOP shall take precedence over protocol for all compliances.
Annual Product Reviews shall be carried out for all the commercial products manufactured during the
year as per defined procedures.
Process is considered for validation, whenever there is a technology transfer of a product from
Formulation development or from the product owner to the manufacturing site. Process Validation is
applicable for the following batches.
New product is manufactured.
Existing product, undergoes a change in process, formula, source of active ingredient or
equipment.
The results of process validation must reveal consistency in product quality attributes.
Validation is initiated with writing of protocol and its approval. The Protocol describes the objective,
scope, validation team with their responsibilities, procedure, product specifications with acceptance
criteria, formula, batch details, equipment to be used with their standard operating procedure numbers,
re-validation criteria, stability, documentation and modalities for preparation of summary report.
Validation is carried out as per protocol.
The results of the various activities are recorded. Based on these results, a validation report is prepared
and a conclusion arrived at after review of the results.
The process is termed validated if defined process meets all the acceptance criteria as mentioned in the
protocol. The validation protocol along with the report is maintained by Quality Assurance after approval
of the report. If at any stage, the process is found to be unacceptable, then a suitable corrective action is
initiated.
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REVALIDATION :
Qualified equipment undergoes major modification, replacement of critical spares that shall affect
equipment performance.
Location of equipment is changed.
Facility Modification.
Modification/ Change in support services.
Change of cleaning agent/method.
Process/ Formula Change.
Change of any critical equipment in the chain of equipments used for product manufacturing.
Change in analytical method etc.
Based on sufficient trend data, the process/ specification parameters are reviewed and tightened.
List of Laboratory equipments, measuring, recording, weighing devices that require to be calibrated has
been drawn out by site technical people in co-ordination with maintenance engineer.
Method of calibration and frequency is defined for each laboratory equipment and critical instruments.
Out of Calibration equipment/ instrument is reported immediately to QA Manager and concerned
department in-charge. Impact of out of calibration is assessed & actions taken. Replacement is recorded.
Calibrated equipments/ Instruments are labelled. Date of calibration and next due is highlighted on the
label. Out of calibration equipments/instruments are conspicuously labeled out of Calibration, not to
be used.
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CLEANING PROCEDURES
Well defined, approved procedures for cleaning of the manufacturing areas are available. The procedure
covers the following:
(i)
(ii)
Frequency of cleaning.
(iii)
(iv)
(v)
(vi)
Cleaning methods.
(vii)
(viii)
The cleaning activity is carried out at specified intervals. The record of cleaning is maintained along with
the cleaning agents used and their concentration. Cleaning activity is checked by responsible person.
For individual equipment, a detailed cleaning procedure has been established. The procedure covers
cleaning procedure to be followed during batch changeover as well as product changeover.
The cleaning was done as per the defined procedure. The samples were collected by both (i) swab
method and (ii) rinse method.
The samples were tested for presence of traces of previous product by the validated method. Carry over
of traces of previous product in the single dose of next product has been proved to meet the norms of
cleaning validation.
Filter cleaning procedures, cleaning frequency for AHUs and dust extraction systems are defined and the
activities are recorded. Regeneration of water system and sanitation of water systems is done as per
defined procedures and frequency.
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C.4.0 DOCUMENTATION
C.4.1 Documentation Preparation & Control
A well-defined system of document control is followed by the site. There is an approved procedure which
explains the system of document preparation, revision, distribution, storage and destruction of the obsolete
documents.
All documents are identified by their title and a unique document number with revision level and date of
next review. Master copies of all the documents are maintained by the site Quality Assurance Department.
Photocopies of the MASTER COPIES are issued to the user departments as a CONTROLLED COPY
and or DISPLAY COPY, which are identified with blue colour stamps. The procedures are reviewed every
two years or and when any change occurs. When document is revised, the master copy is retained as
Obsolete copy and the other copies are destroyed.
QA Manager or his authorized QA personnel is responsible for distribution of documents through document
control system.
There is an approved standard procedure for preparation of Standard operating procedures. Personnel from
the respective departments prepare standard operating procedures.
Specifications for raw materials, packing materials, intermediates and finished products are prepared by the
Quality Control Department personnel, checked by Jr. Manager Quality Control, Approved by QC Head and
authorized by QA Head and finally adopted for commercial production.
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Analytical methods.
Recall procedures
Utility Procedures.
Validation Protocols.
Maintenance Procedures.
Training Procedures.
Quality Policies.
Cleaning Procedures.
Master formula/ Product Manual exists for each product. Batch manufacturing record is prepared as an
extract from the master formula/ product manual. The master formula/ product manual and batch record for
each product is available with Quality Assurance Department. Whenever there is a requirement from
production for a batch record, master batch record is photocopied and each page is authorised by the Quality
Assurance personnel before being issued to production. A logbook for issue of Batch Records is maintained
by QA personnel.
All the completed batch records from production department are returned to Quality Assurance for the final
review and release. Quality Assurance holds the sole responsibility to release the batches. The released
batch records are retained with Quality assurance till one year after the expiry of the product.
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C.5.0 PRODUCTION
C.5.1 Brief description of production operations.
The site is licensed to manufacture Liquid (Oral, Syrups, suspensions, mouthwashes) & External
Preparations as Creams, Ointments, Pastes, Gels, Lotions, Solutions. The site is fully equipped to
manufacture and pack these products.
Flow diagrams of the process- Oral Liquid (Syrups)
APPROVED RAW MATERIALS
DISPENSING
MIXING
FILLING
PACKING
QA RELEASE
DISPATCH
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MIXING
FILLING
PACKING
QA RELEASE
DISPATCH
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GUM SOAKING
MIXING
FILLING
PACKING
QA RELEASE
DISPATCH
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MIXING
FILLING
QA RELEASE
DISPATCH
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batch number of the supplier, analytical report number, date of manufacturing, date of expiry
and the retest date. Anaytical report number is assigned to each lot of material received. The
material is identified with this number. Samples are analysed as per the approved
specifications. If the sample complies with the approved specifications, an APPROVED label
in green is affixed and if it does not meet the specifications , a red REJECTED label is affixed
on the pack (s).
Sampling as per the sampling procedure. Approved materials are transferred from quarantine
to the approved area and the rejected materials are moved to secured rejected material area.
Materials are accepted only from the approved vendors. The list of appoved vendors is
Line clearance procedures are followed for all manufacturing and packing operations. Identity
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In-process control/ tests are carried out as per the frequency and procedure defined in
product specific batch records. In-process checks are conducted by Production and the
Quality assurance, independently at defined intervals.
Intermediate products are analysed and approved by the Quality control prior to the packing
operation. The finished product is transferred to the finished product quarantine area. The
goods are released for despatch after the completion of the finished product analysis and the
review of the batch documents and the analytical reports by Quality Assurance. Products
released by Quality Assurance are transferred to the finished product storage area for
despatch.
Control of non-conforming products
A procedure for control of non-conforming products has been evolved, covering raw
materials, packing materials, intermediates and finished products.
If raw material is not conforming to the specifications, it is labeled rejected and is isolated.
It is sent back to the vendor.
If printed packing material is rejected, it is isolated and destroyed at the site in the presence
of the vendor. A record of the destroyed material is maintained.
If any intermediate or finished product is found to be non-conforming, it is isolated and
marked with the appropriate label. It is then referred to the Quality Assurance Manager, who
investigates the problem. The matter is referred to technical team for action.
Reprocessing and reworking will be considered if there is a need and technically justified.
Details of any non-conforming products and any corrective action taken are recorded and a
record is maintained
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Checking of Containers
& Documents
Quarantine
Area
Under Test
Yellow Label on
all sampled packs
Only Raw
Materials Back to
Supplier only
Sampling by QC
Quality Control
Department
Printed Packaging
Materials Shall be
destroyed at the site
Shifted to Rejected
Area
Goods Receipt
Note Preparation
Rejected Red
Label on all packs
Rejected
Approved
Green Label
Testing as per
Specifications
Approved
Shifted To
Approved Area
Dispensing
Processing
Despatch
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Approved Materials
Requisition from Production
Issuance of
Batch Record
Dispensing
Manufacturing
Processing
Analytical Report
Review (QA)
Batch Record
Review (QA)
In-Process Checks
Despatch
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and
stability
testing.
Instrumental
room
is
temperature
controlled.
Microbiological area is provided with laminar airflow and other facilities to carry out limit tests
and environment monitoring.
The instruments used for the analytical purpose are operated and calibrated as per the
respective operating and calibration procedures.
All working standards used are carefully selected and analysed. They are analysed by two
separate experienced analysts in duplicate, Reference standards are necessary if the assay
method used is a comparative method such as HPLC and In case if any of the required
reference standard is not available in the lab to perform the required test, then a portion of
the sample to be sent to an approved testing lab and get it analyzed in duplicate, so as to
assess their suitability for use as a working standard. The storage conditions for the working
standards as well as their validity for use are specified and all the relevant documents are
maintained.
All volumetric solutions used in tests are prepared from material of a suitable grade in
accordance with the approved procedures.
performed by experienced analysts. The results are verified and records are maintained.
Containers holding volumetric solutions are labelled with details like name of the solution,
strength of solution, date of preparation, date of standardization, use before date, and the
initials of the person who standardized and checked the solution.
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The microbiology laboratory is handled by a qualified microbiologist, who has the appropriate
experience
in
carrying
out
bio-burden
monitoring,
microbial
counts
and
pathogen
characterizations etc.
Staff recruited to the Quality control department undergoes initial training for analyst
validation to ensure the technical competence.
Quality control plays an active role in the validation activities. Quality control department
provides analytical support for process and cleaning validation samples. Quality Assurance
reviews the validation data prior to final approval.
RETENTION/ CONTROL/ RESERVE SAMPLES:
From each batch of a drug product defined quantity in original primary/secondary packing is
randomly selected for retention.
product and stored under the specified storage conditions. These samples subjected for visual
inspection, once in a year.
Defined quantity of each drug substances and excipients also is being stored as a control
samples, retained for minimum for one year after the expiry date.
STABILITY STUDIES:
Stability studies are carried out as per ICH guidelines and pharmacopoeial requirement as
mentioned below.
40oC/75% RH
30oC/65% RH
25oC/60% RH
For developed and existing products, stability is also studied under the specified storage
conditions till the end of shelf life as specified, to confirm its ability to comply with the
specifications set for that product.
The stability chamber are controlled for recording the temperature and humidity conditions.
GPL has sufficient stability chamber with respect to the conditions.
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Complaint records are maintained at the site by the site QA manager. Complete record
contains complaint details, investigation report, response to complainant and closure of
complaint handling process.
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audit team. Out of two inspections in the year, one audit will be conducted as per the readily
available checklist which is a part of the approved SOP for self inspection and the other audit
is carried out without the checklist.
personal discussion with the concerned auditees and verification of the activities being
carried out on the day of the audit and GMP Compliance.
Based on the observations of the audit team, audit leader prepares an Audit Report, listing
system non-conformances, procedural errors and deviations by classifying them as critical,
major and minor. The corrective actions are suggested if possible and the report is forwarded
to the Head of QA / Management representative and thereafter to the Management for Final
Approval.
The audit report is then reviewed and analyzed by the Head QA / Management representative
and the concerned Department Manager. A time bound corrective and preventive action plan
to address non-conformance is agreed upon and initiated. Responsible person to implement
the action plan is also identified. The corrective and preventive action is implemented by the
respective
department
in-charge
and
the
Quality
Assurance
manager
ensures
the
implementation.
The effectiveness of the corrective action is verified subsequent to audit. The nonconformance report raised is closed by the auditor after implementation of the action plan.
Quality Assurance Manager maintains.
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Supersedes
SMF/GP/01
SMF/GP/00
i) Periodic review
SMF/GP/02
SMF/GP/01
SMF/GP/03
SMF/GP/02
SMF/GP/04
SMF/GP/03
SMF/GP/05
SMF/GP/04
v) Periodic review
SMF/GP/06
SMF/GP/05
SMF/GP/06
SMF/GP/07
SMF/GP/08
SMF/GP/07
Changes made
i)
ii)
iii)
iv)
v)
Layouts detailing men/ material movement (General Layout) and AHU Classifications
NOTE :
Confidential
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