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The  Complete  Guide  to  

FDA  Design  Controls


Part  1  &  2

April  26th,  2016


About  the  Presenter
David  Amor  is  the  co-­‐founder  and  CEO   Medgineering  is  a  medtech consulting  firm  
of  Medgineering  &  QuickConsult. based  in  Minneapolis,  MN  focusing  on  
• Adjunct  Professor,  St.  Cloud  State   regulatory  submissions  and  quality  systems.
University  (SCSU)  – MTQ628  
www.medgineering.com
Design  Controls
• 9+  years  of  QA/RA  consulting   www.21cfr820.com
including  DHF  /  risk  mgmt
remediation  projects
• FDA  &  EU  expert  in  QMS
Online  medtech consulting  marketplace  – on  
demand  experts  for  Q&A  and  projects!
@medgineering
david@medgineering.com www.myquickconsult.com
786.546.1806
About  the  Presenter
Jon  Speer  is  the  Founder  &  VP  QA/RA  
of  greenlight.guru.
• 17+  years  in  medical  device  industry
• Product  development   engineer,   greenlight.guru   produces  beautifully  simple  
quality,  design  control  and  risk  management  
quality  manager,  regulatory  
software  exclusively  for  medical  device  
specialist
manufacturers.  We  help  you  bring  higher  
• 40+  products  to  market
quality  devices  to  market  faster  and  with  less  
• Expert  at  QMS  implementations
risk.
• Dozens  of  ISO  audits  &  FDA  
inspections http://greenlight.guru

@creoquality @greenlightguru
Jon.Speer@greenlight.guru
+1  317  960  4280
In  Part  1,  you'll  learn  about  Intended  Use,  User  Needs,  Design  
Inputs,  Design  Reviews,  Design  History  File  (DHF)  and  Risk  
Management.
Specifically:
• The  importance  of  getting  your  intended  use  right  up  front
• The  difference  between  a  user  need  and  a  design  input  
that's  verifiable
• What  stakeholders  need  to  be  involved  in  the  process  and  
why
• When  and  how  many  design  reviews  you  should  hold
• Why  FMEA  alone  is  NOT  risk  management  and  how  to  
integrate  risk  into  the  design  and  development  process
In  Part  2,  you'll  learn  about  Design  Outputs,  Device  Master  
Record  (DMR),  Design  Verification  and  Validation  (V&V),  
Design  Transfer  and  Regulatory  Submissions.
Specifically:
• Why  your  design  outputs  need  to  be  more  than  a  drawing  
and  their  relationship  to  your  DMR
• How  usability  and  human  factors  fits  into  the  overall  product  
development
• Making  sure  you  build  the  correct  device  and  build  it  
correctly  with  design  V&V
• Common  mistakes  people  make  during  design  transfer  to  
production  and  how  to  avoid  them
• When  you  can  and  should  make  your  regulatory  submission
Design  Controls
An  introduction
1997.
21  CFR  820.30.
Design  Controls  – when?
Any  Class  II  or  Class  III  medical  device  developed  in  the  
US  – part  of  quality  system  (QMS).

Investigational  Device  Exemption  (IDE)  – 21  CFR  812.


User  Needs  &  Design  Input
The  FDA  differentiates  between
user  needs  and  technical  requirements
820.30  Design  Controls Design  Planning

Regulation Description
21CFR  820 Quality  System  Regulation
Subpart C Design  Controls

Use  a  development  plan.  Keep  it  short  and  


sweet.  Don’t  overcommit  and  don’t  make  it  too  
prescriptive.
820.30  Design  Controls Design  Planning

The  extent  of  design  and  


development  planning  should  
reflect  company  size  and  
complexity  and  any  outsourcing.

• Refining  is  OK  – especially  for  new  


portfolio  products
• Identify  key  milestones  and  dates  only
• Detail  should  be  dependent  on  risk
• If  outsourcing  development  work,  
identify  the  resources  and  integration
820.30  Design  Controls Design  Planning

“You  state  in  your  response  that  you  plan  on  making  your  
design  plan  more  robust.  We  would  like  to  clarify  that  this  
plan,  as  per  21  CFR  820.30(b),  “shall  identify  and  describe  the  
interface  between  groups  that  provide,  or  result  in,  input  to  
the  design  development  process.  The  plans  shall  be  
reviewed,  updated,  and  approved  as  design  and  
development  evolves.”  The  design  plan  for  Avex  CX2  and  
CXi2,  reviewed  during  the  current  inspection,  was  observed  
to  lack  this  data  including,  but  not  limited  to,  completed  and  
approved  plans  for:  Development,  Clinical,  Risk  Management,  
Quality  Processing,  Manufacturing,  and  Manufacturing  
Qualification”

Discussion   Point:  Lack  of  documented  planning   shows  poor  oversight  


of  your  processes.  Development  planning  may  change  with  new  
information   – up  to  the  point  of  design  freeze.
820.30  Design  Controls Design  Inputs

Regulation Description
21CFR  820 Quality  System  Regulation
Subpart C Design  Controls

Design  inputs  need  to  be  organized  and  


differentiated  between  users,  customers  and  
stakeholders.  Design  inputs  must  be  clear  and  
verifiable.
820.30  Design  Controls Design  Inputs

Design  requirements  are  the  single  


most  important  factor  in  820.30

“There’s  never  time  to  do  it  right  but  


there’s  always  time  to  do  it  over!”
• Comprehensive   – per  risk
• Methodical
• Linked  to  clinical  or  other  rationale
820.30  Design  Controls Design  Inputs

“Drilling  down”  inputs  is  critical.

• Refining  is  OK  – especially  for  new  


portfolio  products
• Identify  key  milestones  and  dates  only
• Detail  should  be  dependent  on  risk
• If  outsourcing  development  work,  
identify  the  resources  and  integration
820.30  Design  Controls Design  Inputs

“Drilling  down”  inputs  is  critical.

User  Needs

Marketing  
Needs
“Concept”  Documents  per  FDA  
Customer  
Guidance  1997  Design  Controls
Needs

Other  
Stakeholder  
Needs
820.30  Design  Controls Design  Inputs

“Drilling  down”  inputs  is  critical.

User  Needs Am  I  ever  going  to  tell  you  


that  I  need  a  catheter  
Marketing   with  a  tensile  strength  of  
Needs 10  +/-­‐ 2  N?

Customer  
Needs

Other  
Stakeholder  
Needs
820.30  Design  Controls Design  Inputs

“Drilling  down”  inputs  is  critical.

User  Needs

Marketing   • Solution  independent


Needs
Product   • Clear
Customer  
Requirements • Concise
Needs • Verifiable
Other  
Stakeholder  
Needs
820.30  Design  Controls Design  Inputs

“Drilling  down”  inputs  is  critical.

User  Needs

Marketing   WHAT? HOW!


Needs
Product  
Specifications
Requirements
Customer  
Needs

Other  
Stakeholder  
Needs
820.30  Design  Controls Design  Inputs

User  Need Design  Input Design  Output


(Requirement) (Requirement) (Specification)

The  catheter  shall  


The  catheter  shall   have  a  torque  ratio   Material  specifications
be  easy  to  
of  1:1  
manipulate.
Test  methods

Drawings
820.30  Design  Controls Design  Inputs
Design  Input This  may  involve  iterative  
(Requirement)
testing  until  the  design  input  
requirement  is  determined.
The  catheter  shall   • TBD  in  initial  drafts  of  DI  
have  a  torque  ratio  
of  1:1  
documents   are  acceptable  –
help  guide  feasibility  testing!
• May  shift  over  time
• Impact  assessment
820.30  Design  Controls Design  Inputs

“Failure  to  establish  and  maintain  


adequate   procedures   to  ensure   that  the  
design  requirements   relating  to  a  device  
are  appropriate  and  address  the  intended  
use  of  the  device,  including  the  needs  of  
the  user  and  patient,  as  required  by  21  CFR  
820.30(c)”

Discussion  Point:  When  you  create  a  user  needs  /  requirement  


document,  are  you  linking  it  back  to  the  intended  use  of  the  
device?  
820.30  Design  Controls Design  Inputs

Design  Inputs  must  be  clear  


(unambiguous)  and  verifiable.

• If  basing  design  inputs  on  a  standard,  


make  sure  the  standard  reference  is  
specific,  clear,  and  test-­‐able
• When  you  think  of  design  inputs,  think  
“engineering”  and  “getting  technical”
• Find  a  resource  for  writing  requirements
820.30  Design  Controls Design  Inputs

Design  Inputs  must  be  clear  


(unambiguous)  and  verifiable.

“Device  shall  be  portable”….


820.30  Design  Controls Design  Inputs

Design  Inputs  must  be  clear  


(unambiguous)  and  verifiable.

“Device  shall  be  compliant  to  ISO  10993-­‐1…”


820.30  Design  Controls Design  Inputs

Design  Inputs  must  be  clear  


(unambiguous)  and  verifiable.

Device  shall  be  formed  into  a  50  mm  


Device  shall  be  flexible VS diameter  coil  and  straightened  out  for  
a  total  of  50  times  with  no  evidence  of  
cracking  or  deformity.

NOTE: assess  the  level  of  granularity  or  detail  based  on  requirement  
criticality/  risk.
820.30  Design  Controls Design  Inputs

F  P  I  S.

• Functional:  what  does  the  device  do?


• Performance:  accuracy,  conditions,  
operational  limits,  reliability,  etc.
• Interface:  what  does  the  device  need  to  have  
to  work  with  accessories  or  external  items?
• Safety:  does  the  device  need  precautionary  
measures  or  safety  margins?
820.30  Design  Controls Design  Inputs

A  note  on  drafting  requirements.


• Language  is  important
a) ‘Shall’  vs.  ‘Should’
a) “Must  have”  vs.  “Nice  to  have”
b) Avoid  “as  applicable”  or  “as  required”  in  final  DI  
• Avoid  contradicting  requirements
• System  à sub-­‐system
a) Particularly  useful  for  contracting
820.30  Design  Controls Design  Inputs

A  note  on  drafting  requirements.


• Avoid  comparative  requirements
• Ex:  “…shall  be  20%  better  than  the  predicate.”
• Avoid  multiple  objectives  in  same  requirement
• Avoid  “NOTEs”!!!
• INCOSE  “Writing  technical  requirements”
820.30  Design  Controls Design  Inputs

Don’t  stress  about  documenting  


design  inputs  in  proof  of  concept  or  
feasibility  phases.  Be  agile!

• FDA  distinguishes  between  R&D  and  


finished  product  – remember   this!  
• Design  inputs  apply  to  the  
commercial  product  (“how  do  I  know  
the  design  is  in  control?”)
The  importance  of  traceability.

“Failure  to  establish  and  maintain  


adequate   procedures   for  verifying  the  
device  design,  as  required  by  21  CFR  
820.30(f).  Specifically,  design  outputs  were  
not  always  evaluated  to  demonstrate  that  
the  outputs  met  design  inputs.”
Risk  Management
An  overview
Risk  Management Design  Controls

Intended  Use  is  important  for  


Design  Controls  &  Risk  
Management.

Risk  Management  &  Design  Controls  


are  about  demonstrating  a  medical  
device  is  SAFE  and  EFFECTIVE.
Risk  Management Design  Controls

Product  Risk  Management  is  a  


cycle,  even  during  product  
development.

• Start  Risk  Management  process  early


• Use  Risk  Management  process  to  
improve  product  design
• Use  Design  Controls  to  support  Risk  
Controls  /  Mitigations
ISO  14971  Risk  Management Key  Terms

RISK  MANAGEMENT -­‐ systematic  application  of  management  


policies,  procedures,  and  practices  to  the  tasks  of  analyzing,  
evaluating,  controlling,  and  monitoring  risk

RISK -­‐ combination  of  the  probability  of  occurrence  of  harm  
and  the  severity  of  that  harm
ISO  14971  Risk  Management Key  Terms

HAZARD -­‐ potential  source  of  harm

HAZARDOUS  SITUATION -­‐ circumstance  in  which  people,  


property,  or  the  environment  are  exposed  to  one  or  more  
hazard(s)

HARM -­‐ physical  injury  or  damage  to  the  health  of  people,  or  
damage  to  property  or  the  environment

SEVERITY -­‐ measure  of  the  possible  consequences  of  a  hazard


ISO  14971  Risk  Management Key  Terms
RISK  ANALYSIS -­‐ systematic  use  of  available  information  to  
identify  hazards  and  to  estimate  the  risk
RISK  ESTIMATION -­‐ process  used  to  assign  values  to  the  
probability  of  occurrence  of  harm  and  the  severity  of  that  harm
RISK  EVALUATION -­‐ process  of  comparing  the  estimated  risk  
against  given  risk  criteria  to  determine  the  acceptability  of  the  
risk
RISK  ASSESSMENT -­‐ overall  process  comprising  a  risk  analysis  
and  a  risk  evaluation
RISK  CONTROL -­‐ process  in  which  decisions  are  made  and  
measures  implemented  by  which  risks  are  reduced  to,  or  
maintained  within,  specified  levels
RESIDUAL  RISK -­‐ risk  remaining  after  risk  control  measures  
have  been  taken
ISO  14971  Risk  Management Process  Overview
ISO  14971  Risk  Management Establish  Framework
ISO  14971  Risk  Management Risk  Analysis
ISO  14971  Risk  Management Risk  Analysis

Include  end-­‐users  as  part  of  the  


process.

Hazards I  can  be  a  valuable  


resource  throughout  the  
Foreseeable   Risk  Management  
Sequence  of   Process!
Events

Hazardous  
Situations

Harms
ISO  14971  Risk  Management Risk  Evaluation
ISO  14971  Risk  Management Risk  Evaluation

Risk  Evaluation  criteria  shall  be  


established  and  should  be  specific  
to  your  product.  

• Use  sources  like  MAUDE  and  other  


industry  databases.
• Consult  with  end-­‐users  to  understand  
true  severity.
• Evaluate  other  similar  products.
• Leverage  standards  and  guidance  
documents.
ISO  14971  Risk  Management Risk  Assessment
ISO  14971  Risk  Management Risk  Assessment
ISO  14971  Risk  Management Risk  Control
ISO  14971  Risk  Management Risk  Control

Risk  Controls  are  means  to  


demonstrate  risks  have  been  
reduced  to  acceptable  levels.  

Priority  of  Risk  Control  options:


1. Inherent  safety  by  design
2. Protective  measures  in  the  medical  
device  itself  or  in  the  manufacturing  
process.
3. Information  for  safety.
Recommend  identifying  Risk  Controls  for  
ALL risks.
ISO  14971  Risk  Management Risk  Control

My  Design  Outputs,  
Design  Verifications,  
and  Design  Validations  
can  be  used  as  Risk  
Control  Measures.
ISO  14971  Risk  Management Risk  Acceptability
ISO  14971  Risk  Management Risk  Acceptability

Medical  benefits  of  the  medical  


device  need  to  outweigh  the  risks  to  
patients  and  end-­‐users.

Have  me  help  you  


with  risk  /  benefit  
analysis  of  your  
product.
ISO  14971  Risk  Management Risk  Management  Report
ISO  14971  Risk  Management Production  /  Post-­‐Production
Design  Review
An  overview
820.30  Design  Controls Design  Review

Regulation Description
21CFR  820 Quality  System  Regulation
Subpart C Design  Controls

Design  reviews  shall  be  planned  and  conducted  


at  appropriate  stages  during  medical  device  
product  development.
820.30  Design  Controls Design  Review

“Failure  to  document   the  design  review  results,  including  


the  date,  in  the  design  history  file,  as  required  by  21  CFR  
820.30(e).”
“Design  reviews  were  not  performed  and/or  documented  
for  the  .  .  .design  project  as  required  in  the  work  
instruction   or  the  design  plan.”
“Design  reviews  were  conducted;  however,  the  records  fail  
to  indicate  the  date  or  dates  the  design  reviews  were  
conducted   and  fail  to  indicate  the  results  of  the  design  
reviews  as  required  in  the  work  instruction.
“However,  there  were  no  records  of  any  design  reviews  
having  been  conducted   after  the  design  changes  were  
implemented  or  transferred  to  production.”
820.30  Design  Controls Design  Review

Timing  of  design  reviews  is  a  


function  of  design  planning.  
Frequency  of  design  reviews  should  
reflect  complexity  of  product  
development.

• All  design  controls  need  to  be  part  of  


design  reviews.
• Design  plan  shall  identify  when  design  
reviews  are  to  happen.
• Design  reviews  shall  include  an  
“independent  reviewer”.
• Design  reviews  shall  include  appropriate  
functions.
Design  History  File
What  goes  in  DHF?
820.30  Design  Controls Design  History  File  (DHF)

Regulation Description
21CFR  820 Quality  System  Regulation
Subpart C Design  Controls

DHF  contains  documented  evidence  that  


medical  device  was  developed  according  to  
established  design  plan.
DHF  contains  all  design  controls.
820.30  Design  Controls Design  History  File  (DHF)

“Failure  to  establish  and  maintain  a  design  


history  file  for  each  type  of  device,  as  
required   by  21  CFR  820.30(j). For  example,  
your  firm  was  unable  to  demonstrate   when  
key  elements  of  a  design  history  file  for  the  
design  project  were  conducted   and  
approved,   such  as  design  inputs,  outputs,  
verification,  validation,  and  design  
transfer.”
820.30  Design  Controls Design  History  File  (DHF)

If  it  isn’t  documented,  then  it  didn’t  


happen.  
Document  all  Design  Controls  and  
keep  records  in  an  organized  DHF.

• Establish  a  DHF  per  product.


• Use  Design  Reviews  to  confirm  Design  
Controls  have  been  documented.  
• Compile  DHF  into  a  “single  source  of  
truth”.
820.30  Design  Controls Design  History  File  (DHF)

It  is  my  responsibility  


to  document   design  
controls  and  maintain  
the  DHF.
Q&A

Part  1
Getting  in  Touch

David  Amor Jon  Speer


@medgineering @creoquality @greenlightguru
david@medgineering.com Jon.Speer@greenlight.guru
786.546.1806 +1  317  960  4280

www.medgineering.com
Quality  Management  Software  
www.21cfr820.com
Exclusively  for  Med  Devices
www.myquickconsult.com
http://greenlight.guru
The  Complete  Guide  to  
FDA  Design  Controls
Part  2
In  Part  2,  you'll  learn  about  Design  Outputs,  Device  Master  
Record  (DMR),  Design  Verification  and  Validation  (V&V),  
Design  Transfer  and  Regulatory  Submissions.
Specifically:
• Why  your  design  outputs  need  to  be  more  than  a  drawing  
and  their  relationship  to  your  DMR
• How  usability  and  human  factors  fits  into  the  overall  product  
development
• Making  sure  you  build  the  correct  device  and  build  it  
correctly  with  design  V&V
• Common  mistakes  people  make  during  design  transfer  to  
production  and  how  to  avoid  them
• When  you  can  and  should  make  your  regulatory  submission
Design  Outputs  &  DMR
Design  Outputs  – more  than  just  drawings!
820.30  Design  Controls Design  Outputs

Regulation Description
21CFR  820 Quality  System  Regulation
Subpart C Design  Controls

Design  outputs  aren’t just  specifications   and  


drawings.
820.30  Design  Controls Design  Outputs

What  can  I  show  you  in  my  books  to  


demonstrate  that  the  design  inputs  are  being  
met/  fulfilled/  satisfied  – how  can  I  prove  it?
820.30  Design  Controls Design  Outputs

• “Establish  and  maintain  procedures  for  


documenting   design  output  in  terms  that  
allow  an  adequate  evaluation  of  
conformance  to  design  input  requirements”

• PLAIN  ENGLISH:  “We  need  a  documented  


way  to  show  how  we  show  that  our  design  
inputs  are  met  – a  drawing,  a  specification,  
results  of  a  test,  methods,  etc.”
820.30  Design  Controls Design  Outputs

• “Design  output  procedures  shall  contain  or  


make  reference  to  acceptance  criteria….”

• PLAIN  ENGLISH:  How  do  we  know  a  design  


input  requirement  is  met?  Acceptance  
criteria.  The  output  must  be  clearly  marked  
to  be  able  to  show  this!
820.30  Design  Controls Design  Outputs

• “and  shall  ensure  that  those  design  outputs  


that  are  essential  for  the  proper  functioning  
of  the  device  are  identified.”

• PLAIN  ENGLISH:  ‘Essential  for  proper  


functioning’   means  you  should  know  the  
Intended  Use  and  what  design  aspects  are  
most  critical  to  meet  it.
820.30  Design  Controls Design  Outputs

Design  outputs:  format  


and  type

Material   Inspection   Service  


Drawings
Specification reports. instructions.

Mfg Batch   Testing   Software  


Instructions Records instructions. code.

QA  specs/   Packaging/   Risk  Mgmt


Test  results.
procedures. Labeling. File
820.30  Design  Controls Design  Outputs

“Failure  to  establish  and  maintain  


adequate   procedures   for  verifying  the  
device  design,  as  required  by  21  CFR  
820.30(f).  Specifically,  design  outputs  were  
not  always  evaluated  to  demonstrate  that  
the  outputs  met  design  inputs.”

Discussion  Point:   Some  companies  use  DOORS  or  other  similar  


requirements  traceability  programs  – what  are  the  pros  and  
cons  with  those  programs?
820.30  Design  Controls Design  Outputs

”For  example,  change  summary  report,  


DP#05-­‐11  – “ICL  Change  of  Packaging  
Solution  from  (b)(4) to  (b)(4)”  lacks  the  
necessary   attachments,  references   and  
reports   necessary  to  compare  the  design  
inputs  with  the  design  outputs  and  
determine  the  adequacy  of  the  
verification.”

Discussion  Point:   Some  companies  use  DOORS  or  other  similar  


requirements  traceability  programs  – what  are  the  pros  and  
cons  with  those  programs?
820.30  Design  Controls Design  Outputs

The  total  finished  design  output  consists  of  the  


device,  its  packaging  and  labeling,  and  the  
device  master  record.  

The  DMR  is  the  “one  stop  shop”  for  design  


outputs,  often  maintained  in  a  DMR  Index.
Design  Verification  &  
Design  Validation
An  overview
820.30  Design  Controls Design  Verification

Design  Input Design  Output


Design  Verification
(Requirement) (Specification)

Did  I  design  my  


medical  device  
correctly?  
820.30  Design  Controls Design  Validation

User  Needs Medical  Device Design  Validation

Did  you  design  the  


correct  medical  
device?
820.30  Design  Controls Design  Verification

“Failure  to  establish  and  maintain   adequate  procedures  


for  verifying  the  device  design. Design  verification   shall  
confirm   that  the  design  output  meets  the  design  input  
requirements,  as  required  by  21  CFR  820.30(f). For  
example:
Your  firm  failed  to  validate  test  methods  implemented  
during  design  verification   testing. These  test  methods  
were  created  in-­‐house  to  verify  your  firm’s  design  inputs;  
however,  they  were  not  based  on  and  did  not  follow  a  
national   standard.
Your  firm  failed  to  follow  its  test  procedure  during  design  
verification   testing.
Your  firm  performed  design  verification   prior  to  
establishing  design  inputs.”
820.30  Design  Controls Design  Validation

“Your  firm  failed  to  establish  (i.e.,  define,  document,   and  


implement)  and  maintain  design  validation  procedures  to  
ensure  that  devices  conform   to  defined  user  needs  and  
intended  uses  and  shall  include  testing  of  production   units  
under  actual  or  simulated  use  conditions,   as  required  by  
21  CFR  820.30(g).
For  example,  your  firm  failed  to  implement  its  established  
procedure  for  design  validation.   .  . However,  prior  to  
commercially   releasing  your  product,   your  firm  failed  to  
conduct   design  validation  of  the  device  constituent  part  of  
this  combination   product,   as  required  by  your  SOP. ”
820.30  Design  Controls Design  Verification

Regulation Description
21CFR  820 Quality  System  Regulation
Subpart C Design  Controls

Design  Verification  demonstrates  that  the  


medical  device  Design  Outputs  meet  the  Design  
Inputs.
820.30  Design  Controls Design  Verification

Design  Verification  shall  provide  


clear,  objective  evidence  that  
Design  Outputs  meet  Design  Inputs

• Consider  Design  Verification  when  


defining  Design  Inputs
• Establish  a  Design  Verification  Plan  (and  
do  so  early)
• Define  verification  methods
• Demonstrate  acceptance  criteria  is  met
820.30  Design  Controls Design  Verification

Design  Input Design  Output


Design  Verification
(Requirement) (Specification)

The  catheter  shall   Material  specifications Plans


have  a  torque  ratio  
of  1:1  
Drawings Methods

Results
820.30  Design  Controls Design  Verification
Design  Verification  Methods

Testing

Design  Verification  
Inspection
Plan

Analysis
820.30  Design  Controls Design  Verification

• Design  Inputs  must  be  clear  


(unambiguous)  and  verifiable.
• Design  Outputs  must  be  defined  so  that  
conformance  to  Design  Inputs  may  be  
demonstrated.
• Need  to  establish  “acceptance  criteria”.
• Establish  (and  validate)  Design  
Verification  methods.
820.30  Design  Controls Design  Verification
Design  Verification  Methods

Testing

Design  Verification  
Inspection Results
Plan

Analysis
820.30  Design  Controls Design  Verification

Design  Input Design  Output


Design  Verification
(Requirement) (Specification)

Did  I  design  my  


medical  device  
correctly?  
820.30  Design  Controls Design  Validation

Regulation Description
21CFR  820 Quality  System  Regulation
Subpart C Design  Controls

Design  Validation   demonstrates  that  the  


medical  device  meets  the  needs  of  the  end-­‐
user(s).
820.30  Design  Controls Design  Validation

Design  Validation  shall  provide  


clear,  objective  evidence  that  the  
medical  device  meets  the  needs  of  
the  end-­‐users.  

• Establish  a  Design  Validation  Plan  (and  


do  so  early)
• Use  regulatory  product  classification
• Involves  “clinical  evaluation”  in  actual  or  
simulated  use  with  actual  end-­‐users
• Product  is  production  equivalent  
• Includes  the  entire  product,  including  
packaging  and  labeling
820.30  Design  Controls Design  Validation

• “Clinical  evaluation”  does  NOT  just  


mean  actual  use.
• Actual  use  will  likely  require  addressing  
additional  regulatory  criteria.
• For  many  devices,  simulated  use  is  more  
than  sufficient.
820.30  Design  Controls Design  Validation

User  Needs Medical  Device Design  Validation

The  catheter  shall   Plans


be  easy  to  
manipulate.
Methods

Results
820.30  Design  Controls Design  Validation
Design  Validation  Methods

TESTING!!

Design  Validation  
Inspection
Plan

Analysis
820.30  Design  Controls Design  Verification

• Design  Inputs  must  be  clear  


(unambiguous)  and  verifiable.
• Design  Outputs  must  be  defined  so  that  
conformance  to  Design  Inputs  may  be  
demonstrated.
• Need  to  establish  “acceptance  criteria”.
• Establish  (and  validate)  Design  
Verification  methods.
820.30  Design  Controls Design  Validation
Design  Validation  Methods

TESTING!!

Design  Validation  
Inspection Results
Plan

Analysis
820.30  Design  Controls Design  Validation

User  Needs Medical  Device Design  Validation

Did  you  design  the  


correct  medical  
device?
Design  Transfer
Not  an  event  – but  a  process!
820.30  Design  Controls Design  Transfer

Regulation Description
21CFR  820 Quality  System  Regulation
Subpart C Design  Controls

Design  transfer  is  the  translation  of  all  of  the  


design  work  to  the  production  and  testing  
processes  that  will  make  it  commercial-­‐izable.
820.30  Design  Controls Design  Transfer
Design  Transfer  Myths
• Myth:    Design  Transfer   is  an  event
• Reality:    Design  Transfer  is  an  iterative,  continuous  process

• Myth:    Design  Transfer   is  Operations’  responsibility


• Reality:    Design  Transfer  is  a  collaborative  effort  between  all  
of  the  functions  involved  in  design  and  development

• Myth:    Design  Transfer   occurs  after  “design  freeze”


• Reality:    Design  Transfer  begins  early  in  design  and  
development,  and  is  part  of  design  refinements  (design  
changes)  that  lead  to  a  “final”  design.    Design  Transfer  can  not  
end  until  the  DMR  is  finalized.
820.30  Design  Controls Design  Transfer
Source  of  Misconceptions
21  CFR  Part  820.30  Design  Control
b) Design  &  Development   Planning Which  gets  visualized  as:
c) Design  Input
d) Design  Output
e) Design  R eview Planning
Design   Design   Design   Design   Design   Design  
f) Design  Verification Input Output Review Verification Validation Transfer

g) Design  Validation
h) Design  Transfer
i) Design  Changes

But  the  p rocess  really  looks  more  like  this:


Design  &  Development  Planning

Design  Input

Design  Output

Design  Review

Design  V erification

Design  V alidation

Design  Transfer
820.30  Design  Controls Design  Transfer
Design  Transfer  Completion
• All  Device  Master  Record  (DMR)  elements   reviewed,   • All  equipment    identified  and  calibrated  and  
approved,  and  production  r eleased maintenance   procedures  are  in  place

• All  (DMR)  elements   are  managed  under  formal   • Manufacturing  personnel  and  inspectors  have  been  
change  control trained

• Risk  assessments   completed   and  all  identified  risks   • All  supplier  agreements   and  qualifications  are  
appropriately  dispositioned complete

• Defined  and  implemented   test  strategy  for  incoming,   • Procedures  in  place   to  ensure  control  of  device  
in-­‐process,  and  final  acceptance   testing handling,  storage  and  distribution  of  product

• Plans  in  place  to  monitor  and/or  control  features   • Procedures  in  place   to  ensure  identification  and  
identified  as  critical  to  quality traceability  of  product

• Process  validation  complete • Design  verification  testing  performed  and  


demonstrates  design  outputs  meet    design  inputs
• Test  methods  validated  and  complete
• Design  validation  testing  performed  demonstrates  
design  meets  user  needs  &  intended  uses
• Inspection  procedures,  visual  inspections,   and  
workmanship  standards  are  complete
• All  elements   of  the  Design  Transfer  Plan  have  been  
completed   or  otherwise  addressed
• Installation  and  servicing  procedures  are  complete
820.30  Design  Controls Design  Transfer

“There  is  no  assurance  that  a  design  transfer  procedure  


has  been  adequately  established  for  [PRODUCT]  to  […]  
ensure  an  accurate  translation   of  the  device  design  and  
conformance   to  predefined  user  needs  and  intended  
uses.    

There  is  no  assurance  that  design  transfer  procedures  


have  been  adequately  established  for  each  
rework/reconfiguration   process  of  Passport  V  Monitor  to  
ensure  an  accurate  translation   of  the  device  design.”

Discussion  Point:   a  process  should  identify  what  represents  


“accurate  translation”  of  the  device  design.
Regulatory  Submissions
The  DHF  forms  the  basis  for  your  objective  evidence  
that  the  device  has  been  designed  to  be
safe  and  effective
United  States

DOJ  enforcement

Who  are  the  regulators?

European  Union
• Classified  according  to  risk  and  
“criticality”  to  patient/  end-­‐user
US  Device   • (3)  letter  code  groupings  with  names  
Classifications and  attributes
21  CFR  860 • Used  to  track  adverse  events  and  
field  actions
• As  new  classification  product  codes  
are  created,  a  device  may  be  re-­‐
assigned  into  a  new  product  code.  
• Guidance  exists  for  identifying  the  
scope  and  critical  aspects  of  a  
product  code.
Class  I Class  II Class  III
not  intended  to  help   more  critical   than  Class  I   support  or  sustain  human  
support  or  sustain  life  or  be   but  designed  to  perform  as   life,  are  of  substantial  
substantially  important  in   indicated  without  causing   importance  in  preventing  
preventing  impairment   to   injury  or  harm  to  patient  or   impairment  of  human  
human  health,   and  may  not   user. health,  or  present  a  
present  an  unreasonable   potential,  unreasonable   risk  
risk  of  illness  or  injury of  illness  or  injury

LOW  RISK MEDIUM RISK HIGH  RISK

General  Controls General  Controls    +   General  Controls  


Special  Controls +  Premarket  Approval  
510(k) (PMA)
General  Controls

• Basic  requirements  for  all  medical  device  companies  per  MDA


• Applies  to  all devices;  Class  I  only has  to  follow  general  
controls  (with  some  exceptions)
• Includes  provisions:
• Adulteration
• Misbranding
• Device  registration  and  listing
• Premarketing  notification  (exemptions  in  XXX.9s)
• Banned  devices
• Notification  – repair,  replacement,  refund
• Records  and  reports
• Restricted  devices
• GMPs  (Quality  System  Regulation)-­‐ some  exemption
Class  I Class  II Class  III
General  controls  +  510(k)  or  PMA  
Submitting  a   depending  on  risk  and  intended  use  
of  device
Medical  Device  in  
United  States Implement  a  quality  management  
system

Why  do  I  need  to  comply  to  ISO  13485?

Registration  &  
21  CFR  820  (QSR) Submission
The  2  main  pathways  of  getting  to  US  market.
Pre-­‐market   Pre-­‐market  
notification approval  (PMA)
The  510(k)  – Substantial  Equivalence
Substantial
Equivalence = Intended  Use & Technological  
Characteristics

Different  
Technological  

+
Characteristics
or
No  new  safety    or  
efficacy  concerns
Pre-­‐market  
Traditional
notification

Special  (20%)

Abbreviated  (5%)
510(k)  Content  (21  CFR  807.87)

• Admin  paperwork  (cover  pages,  statements


• Device  information:  name,  intended  use,  classification
• Company  information:  location,  certifications
• Labeling  
• Substantial  equivalence  assessment
o Device  specifications  and  reference  applicable   guidance  documents,  
special  controls,  or  standards;  photographs  or  engineering   drawings
o Testing  data
o Comparison  charts
• Information  on  biocompatibility,  sterilization,  materials  analysis,  
etc.
510(k)  Data

http://www.emergogroup.com/resources/research/fda-­‐510k-­‐review-­‐times-­‐research
The  SE  Letter.
Q&A

Part  2
Getting  in  Touch

David  Amor Jon  Speer


@medgineering @creoquality @greenlightguru
david@medgineering.com Jon.Speer@greenlight.guru
786.546.1806 +1  317  960  4280

www.medgineering.com
Quality  Management  Software  
www.21cfr820.com
Exclusively  for  Med  Devices
www.myquickconsult.com
http://greenlight.guru

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