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Objectives

§Introduce current Good Manufacturing Practices


(cGMP)
§Understand the Major Aspects of GMP
§Learn the 10 Golden Rules of GMP

Definitions Who Regulates the GMP Rules?


• The governments of different countries have formed regulatory authorities to
make GMP regulations about how pharmaceutical and life science products are
• cGMP – current Good Manufacturing Practice made. The International Council for Harmonization of Technical
Requirements for Pharmaceuticals for Human Use (ICH) brings together these
• GCLP - Good Control Laboratory Practice regulatory authorities and pharmaceutical industry to harmonize regulations
and enforcement. The Pharmaceutical Inspection Cooperation/Scheme (PIC/s)
• GAMP- Good Automated Manufacturing Practice organization leads the international development, implementation and
maintenance of harmonized GMP standards.
• GxP- Abstract term to cover good practices in general
• The health regulatory authorities, like the FDA Philippines, performs audits of
within pharmaceutical environment manufacturing sites to check that GMP regulations are followed, i.e. PIC/S GMP
Guidelines for Medicinal Products.
• GDSP- Good Distribution and Storage Practice
• The regulatory authorities also provide a framework for the regulation of
medical goods to ensure the quality, safety and efficacy of medicines and
ensure the quality, safety and performance of medical devices.

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.

Overview of Quality Assurance


Good Manufacturing Practice (GMP) Quality by Design
• The GMP rules have their origins in the US FDA laws that were passed in the USA in 1938.
These laws mandated that new drugs must be safe and that manufacturing methods,
facilities, and controls be “ adequate” • A system approach to development that begins with predefined
• The laws were introduced in response to the elixir sulfanilamide crisis that killed objectives and emphasizes product and process understanding and
107people, mostly children due to contamination of Glycerine with Di ethylene glycol
and process control, based on sound science and quality risk
• The GMP rules were further strengthened after the Winthrop Chemical Company
produced sulfathiazole tablets contaminated with phenobarbital in 1940, which killed or management.
injured over 300 people
• The Clothier report in the UK in 1972, based upon the Evans medical due to sterilization
• Products must be designed and developed with GMP and GCLP in
issues of a dextrose infusion that caused 5 deaths of children prompted the first UK mind.
orange guide, which formed the basis of the current EU GMP (and PIC/s) regulations

The GMP rules are there to ensure that drugs and


medical devices are safe and effective.
Overview of Quality Assurance Overview of Quality Assurance
Manufacturing Finished product
• Production and control operations should be clearly specified • The finished product should be correctly processed and checked,
• cGMP compliant procedures should be made for the manufacture, according to the defined procedures.
supply, and use of the correct starting and packaging materials. • Products should not be sold or supplied before an authorized person
• All necessary controls on intermediate products, and any other in- has certified that each production batch has appropriate quality
process controls and validations must be carried out. • Products should be stored, distributed and subsequently handled so
that quality is maintained throughout their shelf life.

Overview of Quality assurance Overview of Quality Assurance


Self-inspection Responsibilities

• 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.

What does Quality Control department do? Foundations of Quality Control


• Quality Control (QC) shall ensure that raw materials and manufactured
products are released after verification of documents as per internal • The foundations of QC is having :
release procedures and under proper authorization
• Adequate Facilities
• QC is responsible for sampling, specifications, testing, data reporting
and data integrity • Trained Personnel
• As well as the organization, documentation and release procedures
which ensure that the necessary and relevant tests are carried out
before product release.

Foundations of Quality Control Foundations of Quality Control


Procedures Testing
Ensure approved procedures are available for:
• Sampling of raw materials Test methods must be available and validated.
• Self-inspection of at least personnel premises including:
1) personnel, 2) facilities and maintenance of buildings and
equipment, 3) storage of stating materials, and finished products,
4) equipment, 5) production and in-process controls,6) QC,
7) documentation, 8) sanitation and hygiene, 9) validation and
revalidation programs, 10) calibration of instruments or
measurement systems, 11) recall procedures and complaints
management,12) labels control, results of previous self-
inspections and any corrective steps taken
• Testing starting materials
• Testing of packaging materials
• Testing intermediate, bulk and finished products and,
where appropriate
• Monitoring environmental conditions
Foundations of Quality Control Foundations of Quality Control
Starting materials Records

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.

Foundations of Quality Control Foundations of Quality Control


Finished Product Release
• The finished product should contain active ingredients complying No batch of product can be released for sale or supply prior to
with the qualitative composition of the marketing authorization
certification by an authorized person that it is in accordance
• Finished product should be of the purity required and enclosed within with the requirements of the license.
their proper container and correctly labeled
• Records should be made of the results of inspection and that testing
of materials, intermediate, bulk, and finished products was formally
assessed against specifications
• Product assessment should include a review and evaluation of
relevant production documentation and assessment of any deviations
from specified procedures.

Foundations of Quality Control


Sampling GMP and the law
• Regulatory authorities have the power to :
• Sufficient samples of starting materials and products should • Stop manufacturers from producing
be retained to permit full release testing twice, with the
exception of sterility testing. • Stop the sale of products
• Close down the plant and facilities
• Suspend or revoke manufacturing licenses
• Prevent products from entering a country
• Bring charges which could result in fines and/or jail
sentences

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 (continue)


Personnel Training in GMP guidelines is recognized verify important. During an audit, an
• A systems and adherence to GMP guidelines relies auditor might ask to see:
exclusively on people. • Competency matrices – identifying the skills and training required for each role in the
organizations
• Having the right number of personnel: • Training records to show when someone was trained and what they were trained on
These records must be kept for everyone who works in a GMP area, including :
• The GMP guidelines recognize how critical people are qContractors – such as sales people and cleaners, are a common source of non-
ensuring product quality. compliance. It is critical that contracting companies supply only GMP trained personnel
to work in production areas. Untrained staff, filling in for someone who is away, will not
• To meet the GMP requirements, it’s essential to have : understand how much they can impact product quality.
EX: a piping contractor, installing a filler housing unknowingly left the waste materials in
• The right number if people, and the water systems. The system supplied sterile water for the manufacture of injectable
drugs. However, the water system would contain an on-line Total Organic Carbon (TOC) or a
• That they have the right qualifications and experience to do conductivity meter to detect and dump un-sterile water before it gets into the distribution
the job loop. Also, QC tests on the water would detect such a problem before any drugs were
released.
To meet these requirements it is essential that what “ right” qCleaners
means has been identified for every functions and process. qSupplier’s representatives who visit frequently such as equipment service engineers

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

Premises and Equipment


Premises and Equipment
§ Ensure manufacturing equipment :
Design
§ Is designed, located, and maintained to suit its intended use The GMP guidelines that manufacturing facilities are designed to
§ Is designed so that it can be easily and thoroughly cleaned minimize product contamination and mix-ups.
qUsing covered ceilings, floor and corners within manufacturing areas
§ Has procedures for how and when to clean each place of minimizes debris and thus bacterial accumulation
equipment that can impact product quality
qMachines should be located to allow easy access for regular
§ Has procedures that clearly state who is responsible for the maintenance
cleaning and have cleaning records qDedicated lines and facilities i.e. physical separation, should be used
when manufacturing products that have high cross-contamination
potential
Premises and equipment
Premises and Equipment
Equipment placement
Premises Design
Example
• Modern warehouses at commercial manufacturing sites are today
• In one company, the maintenance schedule for a piece of production automated and their status and location are controlled by an
equipment required the oil to be changed and 55 sensor points to be enterprise management system. A modern warehouse is divided into
checked every three months. a receiving area and a storage area in which there are specific areas to
store rejected recalled or returned materials or products. Optimally,
• During an audit, the auditor discovered that this was only being done rejected product would be kept in a caged area.
during the annual shutdown period. Why?
• Again the aim is to prevent contamination and mix-ups. It would ne
• The machine has been installed very close to the wall. The very easy for a batch of recalled products to be accidentally shipped
maintenance could not access the back of the machine when it was out to customers if the recalled products were not kept physically
moved away from the wall, This could only be done during annual separate from the final products in the warehouse,
shutdown, when a mobile crane was available to lift the machine. • QC labs are separate from production areas.

Premises and Equipment


Premises and Equipment
Facilities
• Qualification and validation should establish and provide documentary
• The facilities should be designed and equipped to prevent entry of evidence that:
pests or animals. • The premises, supporting utilities, equipment and processes have been designed in
accordance with the requirements for GMP (design qualification or DQ)
• Steps should be taken to prevent entry of unauthorized personnel • The premises supporting utilities and equipment have been built and installed in
compliance with their design specifications (operational qualification or OQ)
• Where special storage conditions are required (e.g. temperature, • A specific process will consistently produce a product that meets its predetermined
humidity) these conditions should be provided , checked and specifications and quality attributes (process validation or PV, also called performance
qualifications or PQ)
monitored and also validated (e.g. temperature mapping) on a
periodic basis. Any aspect of operation including significant changes to the premises, facilities,
equipment or processes which may affect the quality of the product , directly or
indirectly should be qualified and validated.
Particular attention should be paid to the validation of analytical test methods,
automated systems and cleaning procedures.
The responsibility for performing validation should be defined.

Premises and Equipment


Scenario
Data Collecting equipment
• The GMP guidelines require equipment to be fit for purpose. If the • Dana was required to weigh completed products to ensure
weighing step is critical to product quality, then equipment should be used that they met specifications. They were supposed to weigh
that will ensure an appropriate level of accuracy.
• A good practice is to display the usable range on all scales. A s a rule of 500g +/-2g
thumb, the minimum weight that the scale can introduce should be less
than 0.5% error. • She first weighed herself on the large scales in the
• This means if a scale can weigh up to 1000g and the scale interval is to 0.1g, warehouse. These scales were used to weigh packaged goods
then the minimum 20g may be weighed on that scale. to determine shipping costs.
• If the scale rounded to say 0.5g intervals then the minimum permissible
weight should be 100g • Dana then held a product and weighed herself again.
• The above is only a rule of thumb – all scales should be validated for • She calculated the weight of the product by subtracting the
their intended purpose.
second from the first.

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.

Documentation essentials Production


• The GMP guidelines for documentation state that documents must The critical aspects of production in GMP environment are:
• Be approved, dated, and signed by authorized staff • The prevention of cross-contamination in production areas
• Be designed, prepared, reviewed, approved, and distributed using • Validation-so processes are understood and controlled
controlled processes • Starting materials
• Be unambiguous • Processing operations, both intermediate and bulk products
• Be regularly reviewed and kept up to date (typically every 2-3 years) • Packaging materials and operations
• Not have hand-written notes attached • Finished products
• Be retained for a predetermined period • Rejected, recovered, and returned materials
• Have an inventory of current documents in use

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.

Quality Control QC is not confined to a lab


The quality control (QC) aspect of a quality management system is • Quality control should be involved in all decisions which may impact
concerned with: product quality.
• Protocol sampling • The independence of a quality control from production is considered
• Testing raw materials and final produces against specification a fundamental GMP requirement.
• Organization • During the investigation of the Pan Pharmaceuticals case, auditors
• Documentation found that the managing director was signing off QC tests and
• Product release procedures releasing product from production. The concentration of the active
pharmaceutical ingredients in the products varied from 0.1% to 70.0%
• On-going stability program
of the required concentration. The company was closed down by the
QC ensures that the necessary and relevant tests are carried out, and test TGA.
materials and products are not released for use, sale or supply, until their
quality has been judged satisfactory.

QC is at the core of every process QC from start to finish


• All quality control procedures should be established • Quality control runs through manufacturing from start to finish (S2F),
validated and implemented. it continues after the product has been manufactured.
• Reference samples of materials and products must be kept. • Reference samples of materials and products must be of a size
sufficient to permit full release testing to be performed twice with the
• Monitoring product stability is a fundamental responsibility exception of sterility testing.
of QC, Note:
• QC must participate in the investigation of complaints related The EU also requires that the analytical materials and equipment be available to
to the quality of the product. carry our full testing one year past expiry.

• Testing methods should be validated.


Responsibilities – Contract Giver
Contract Manufacture • The GMP guidelines apply the following responsibilities to the
contract giver:
• Contract manufacture and analysis must be correctly and • The contract giver is responsible for assessing the competence of
completely defined, agreed and controlled to a void the contract acceptor to successfully carry out work required and
ensuring that GMP is followed.
misunderstandings that could result in a product or work of • The contract giver must ensure that all products and materials
unsatisfactory quality. delivered to them by the contract acceptor comply with their
• A written contract must exist that establishes the duties of specifications and that the products have been released by an
authorized person.
each party.
The key point is that it’s the contract giver (i.e. the customer) who has
• Specific responsibilities for product personnel must be the responsibility to ensure that products are manufactured and
considered and documented. released according to GMP guidelines. The responsibility cannot be
delegated to the contract manufacturer.

Responsibilities –Contract Acceptor Complaints and Product recall


• The contract acceptor must have adequate premises and equipment, • Responsibilities
knowledge and experience, and competent personnel to carry out • There must be a designed person responsible for handling the
satisfactory the work ordered by the contract giver. complaints and deciding the measures to be taken.
• The contract acceptor must ensure that all products or materials • What must happen?
delivered are suitable for their intended purpose. • Ensure written procedures are available describing the action to be
• The contract acceptor must not pass to a third party any of the work taken including the need to consider a recall in the case of a
entrusted under the contract without the contract giver’s prior complaints concerning a possible product defect.
evaluation and approval of the arrangements. • Record all complaints and investigate thoroughly. The investigation
details and results, including risk assessment, root cause analysis
and remedial, corrective and preventive actions(s), must be
recorded, reviewed and approved by the responsible designated
quality staff.

Complaints and Product Recalls


Investigation
Traceability
• If a product defect is discovered or suspected in batch, other batches
• Distribution records must:
must be checked in order to determine whether they were also
affected. • Be readily available
• Contain sufficient information on wholesalers and directly
• In particular, other batches which may contain reworks of a defective
supplied customers, including those for exported products and
batch must be investigated.
medical samples
• RECORD KEEPING
• Product reconciliation after a recall
• You must record all the decision and measures taken as a result of a
• A reconsolidation of affected products must be performed to ensure
complaint and reference the corresponding batch records.
all recalled products have actually been received
• You must review complaint records regularly for any indication of
• Regular audits of the recall process must also occur to evaluate the
specific or recurring problems requiring attention and possible recall.
effectiveness of 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.

Golden Rule 6 - Responsibilities Golden Rule 7: Hygiene


• Create clearly defined responsibilities and ensure the
development and demonstration of job competence.
• The Key point here is that everyone must know
who is responsible for what.

Golden Rule 8:Maintenance


Golden Rule 9: Quality

• 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!

Things go wrong! Case 2 Case Example 3


• Fire alarm in factory! • Semi-automated process for protein capture
• Clean room operators evaluate and assemble in parking lot • Cell culture –harvest (centrifuge, cell lysis and capture
• Return to clean room but do not change gowns! chromatography column) – protein eluted to eluate tank – clean
• Procedures requires daily change of gowns column with NaOH solution
• Does not cover fire evacuation • NaOH accidentally run into eluate tank
• High levels of microbial contamination in clean room • Batch was lost
• Lack of awareness! • Problem occurred twice with a different operator each time
Lesson learned:
Awareness of concepts is as important as “how to” training

How was this resolved? Lessons learned


• Automated system should prevent this error • Operators may try to take short cuts to save time, but may lack an
• BUT-automated process overridden by operator understanding of why they shouldn’t!
• Root cause-operator error-operator counseled and re-trained • The automation is used to minimize the impact of operator error, but
the if the software can be overridden by the operators
• Problem occurred again – different operator but the same root cause!
• Operators should not be allowed to override the automated process
• Automation fix sufficient? What if both operators make the same
mistake? • Override should be done by supervisor or system administrator as
approved change or planned deviation

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