Professional Documents
Culture Documents
What is GMP?
Risk Based approach • The acronym GMP is used internationally to describe a set of principles
• The regulatory framework is based on a risk management and procedures which, when followed by manufacturers of medical
goods, help ensure that the products manufactured will have the
approach, designed to ensure public health and safety. required quality.
• At the same time the framework frees industr y from • GMP is the part of the quality management which ensures that
unnecessary regulatory burden. However the framework products are consistently produced and controlled to the quality
should not be seen as an alternative to compliance with standards appropriate to their intended use and as required by the
regulations. marketing authorization clinical trial authorization or product
specification. GMP is concerned with both production and quality
control , plus product and process design.
• A basic tenet of GMP is that quality cannot be tested into a batch of
product but must be built into each batch of product during all stages of
the manufacturing process.
• There should be a procedure for self-inspection which • Managerial responsibilities should be clearly specified
regularly appraises the effectiveness and applicability and documented
of the quality assurance system.
Samples of starting materials, packaging materials, intermediate • Records should be maintained which demonstrate that all
products, bulk and finished products should be drawn and tested by required sampling, inspections and testing procedures have
quality control. been performed.
• Ensure you record and investigate any deviations.
The nine sections of the GMP guidelines Quality Management System (QMS)
• Experience has taught regulators that it is not just the steps involved in • QMS is the responsibility of senior management, but it requires the
product manufacture that are important. GMP must be a holistic process
that controls everything that can impact product quality. participation and commitment of all staff
• There are 9 key aspects that need to be controlled in order for GMP to be • International standards:
in place: • Regulatory guidance on quality management comes from ICH Q10
1. Quality management system Pharmaceutical Quality System that has been harmonized and accepted by all
2. Personnel the major authorities worldwide
3. Premises and equipment
4. Documentation • Governance
5. Production • QMS is the high level governance of quality by a company. It envelopes GMP,
6. Quality control quality assurance , quality control, produce quality review and quality risk
7. Contract manufacturing and analysis management (QRM)
8. Complaints, returns and product recalls
9. Self-inspection
Product Quality Review Quality Risk Management
• Product quality reviews are regular periodic or rolling review of all • Quality risk management is a systematic process for the assessment,
licensed medicinal products, including export only products. control, communication and review of risks to the quality of the
Regulatory authorities require annual product reviews (APRs) as product.
formal reports for each licensed product, each year. • Risk must be assessed based on scientific knowledge and impact on
• They are conducted with the objective of: patient safety.
• Verifying the consistency of the existing process • Level of effort of risk management needs to be commensurate with
• The appropriateness of current specifications for both starting materials and the level of risk.
finished product
• Highlight any trends; and
• Identify product and process improvements
Personnel
Personnel
GMP essentials
Good Hygiene
Because personnel are such a critical part of GMP, the GMP guideline specify
that :
• All staff must have the education, experience and training to perform their
duties • It is critical that staff reduce the risk of introducing infections and bacteria
• Documentary evidence of this must be maintained, including resumes, into the area where products are being made. This includes:
professional qualifications, and training records • Reporting open sores of any illness to their supervisor
• An organizational chart is mandatory (and can be subject to auditing) • Appropriate washing of their hands
• The responsibilities of each position must be defined and documented
• No eating drinking, chewing or smoking and no storage of food, drink,
• The head of production and quality control must be independent from
each other smoking materials or personal medication in production and storage areas
• Good personal hygiene is critical- staff must be trained and equipped to • All personnel entering the manufacturing areas should wear clothing
ensure good personal hygiene appropriate for the area and the operations to eb carried out
• Unhygienic practices with the manufacturing areas or other areas where
product may be adversely affected should be forbidden
Solution Documentation
Documentation is an essential part of manufacturing a product. It performs
several functions:
• She should have requested a scale that had a • It held the people who make the product by providing them with
range from 0-1kg and displayed x.xg instructions on the steps to follow so that nothing is left to memory
• It shows auditors what the proven process for manufacturing a particular
product is and that the recess was followed.
• It provides data for any investigation if there is a problem with a batch of
product
• It makes sure that everyone, internal and external to the company, knows
how a particular product is made and the quality checks that must be
performed during ,manufacture to ensure everything is working as it
should
• It is used to assess the quality of the product manufactured for release
Documentation Documentation
• Documents can be hard copy, electronic or a hybrid of the two forms. In a
manufacturing environment you will typically need the following types of • The GMP guidance requires log books to be kept for major or critical
documents.
equipment.
• This may vary according to the type of products manufactured:
• The following must be recorded in the log books:
• Specifications, both for raw materials and for the finished product
• Equipment usage
• Manufacturing formulae and instructions
• Processing and packaging instructions • Validation activities
• Procedures an work instructions • Calibrations
• Records • Planned and unplanned maintenance
• Site Master file • Cleaning
Any of these documents maybe reviewed during an audit. Each entry must be dated and signed by the person who performed the task.
Documentation
Document Control
Things that go wrong with documents
• It is a GMP requirement that the document that • Here are some examples of things that can go wrong if documents are
not controlled-you have probably experienced some of them.
controls the manufacture of products must be • If different versions of a document are not identified using a common
controlled themselves. This prevent mistakes in process then several different versions of the same document may be
in circulation. No one knows which is the “right” one.
documents that could impact product quality. • If the review process is not formalized then simple mistakes such as
the required temperature for a process may b e listed as different
• Controlled documents must be prepared , values in different documents e.g. 44 °C in a procedure and 44 °C on a
reviewed, distributed and changed using a for the process. Or the temperature is stated as °C but the
temperature measurement is °F. In pharmaceutical manufacturing
documented process. temperatures should always be stated and recorded in °C.
Production
Production
Containment and Cross-contamination
•GMP is that part of quality assurance which • Within the production areas of a company, the GMP
ensures that products are consistently produced guidelines focus on preventing contamination, cross
and controlled t the quality standards contamination and mix-ups.
appropriate to their intended use as required by • GMP guidelines require that you should understand
the license or marketing authorization. and control all production processes so that you can
be sure of the outcomes of those processes.
Production Production
• People are a major source of a product contamination
• Process operations follow clearly defined and • Access to production areas must be restricted to authorized
proven procedures. personnel.
• Production personnel must be trained in appropriate personnel
• Procedures must comply with GMP principles in hygiene and clothing procedures e.g. wearing hair nets and shoe
order to manufacture products of the required covers
quality. • Technical systems such as swipe card access to areas, air locks and
pressure differentials should also be used to prevent cross
contamination
Production Production
Labeling Process
The process should :
All materials , bulk containers, supplies and major items
of equipment used should be labeled with: • Be clearly defined;
• Clearly defined materials, equipment use and
• The product or material name personnel involved and timing of activities must be
• Its strength fully traceable;
• The batch number • Have the activities documented in real time by the
person performing the tasks;
• The stage production
• Have secondary verification of critical steps in the
process.
Self-inspection
• The following should be evaluated for conformity to QA and GMP principles:
• Personnel matters, for example the training system
The 10 Golden Rules of GMP
• Premises
• Equipment , calibration records and procedures • Golden Rule 1: Facility Design
• Documentation • Ensure that productivity considerations, product quality, and the
• Production safety of products and employees are incorporated in the design and
• Quality control construction of all processes, facilities and equipment
• Distribution • Layout of design need to minimize the risk of error, permit
• Complaints and recalls-is the distribution list current effective cleaning and maintenance such that there is no adverse
• And even the self-inspection process! effect on product quality. Facilities should also be designed to
All self inspections must be records. The quality system itself should also be part of the self-
inspection program, including deviation investigations, the CAPA system, training document prevent mix-ups and cross contamination
control and archives, quality metric, etc. Reports must contain all the observations made
during the inspections and, where applicable, proposals for corrective measures • The key point is that is s essential to get the design of the plant
A complete follow-up action plan must be adhered to. Progress of the action plan should be right from the start.
regularly monitored to ensure agreed actions are completed.
Golden Rule 2- Validation Golden Rule 3 - Procedures
• Ensure that systems achieve what they are designed • Prepare detailed procedures that provide a
to do by validating processes and testing step-by-step road map to controlling and
methods and qualifying facilities and maintain consistent performance.
equipment
Golden Rule 4 – Training and Development Golden Rule 5 – Good Record Keeping
• A common problem is that the procedures are • Accurately record process events in real time for
written but no one follows them. compliance and traceabilty.
• Ensure people are appropriately trained in the task • From an auditor’s perspective, if it isn’t written
they are to perform. down then it did not happen.
• Ensure that all facilities and equipment are • Build quality into products by controlling product
properly maintained and recorded. components and product-related processes, such as
marketing, manufacturing , testing, packing, labeling
and product distribution.
• Also build quality into the design of the product and
of the processes
Golden Rule 10: AUDITS Case Study-Hygiene and Cleaning
• Plan regular self-inspection audits to ensure • Contamination in a clean room by an organism normally found in
water and soil (dirt):
compliance and performance.
• Operators walking out of clean room wearing dedicated shoes!
• Failure to clean frequent spillages
• Condensate from heat exchanger dripping on to a clean room floor
Lessons learned:
Dedicated shoes are dedicated to a specific clean room suite and to a
specific operator
Spillage and leakage must be dealt with immediately!