Professional Documents
Culture Documents
in ASEAN Harmonization
Guideline?
by
Pramote Cholayudth
VALITECH
Tel 08-1932-2374
Email: cpramote2000@yahoo.com
July 2008 1
Topic Outline
Samp # 1
Process Samp # 2
Samp # 3
3
A Stable Process Model
4
A Capable/Non-Capable Process Model
5
Control Chart Limits
μ+3σx UCL
μ Sampling Distribution
μ-3σx LCL
σ
σx =
n
6
Control Chart Limits
In control Out of control
Process Process center
is stable has shifted
μ+3σx UCL •
•
•
• •
μ
• •
• • •
•
μ-3σx LCL
7
Control Chart Limits
USL
μ+3σx UCL
USL & LSL = Upper & Lower Specification Limits for Average
UCL & LCL = Upper & Lower Control Limits for Average
CL = Center Line = Central Line
8
Process Capability
10
Process Capability (Cp) Index (CpK)
Process Target
150 mg/tab CL
Process Range
144 mg/tab LCL
140 mg/tab LSL
USL − LSL
Cp =
σ x = 2 UCL = 150 + 3 x 2 = 156 6SD
⎛ USL − x x − LSL ⎞
LCL = 150 − 3 x 2 = 144 CpK = Min⎜⎜ , ⎟
⎝ 3SD 3SD ⎟⎠ 14
In-Process Control Using Control Chart Limits
Process is on-going
⎛ USL − x x − LSL ⎞
CpK = Min⎜⎜ , ⎟
⎟
⎝ 3SD 3SD ⎠
USL − LSL
Cp =
6SD
140 − 60
= = 2.2
36
15
Process Capability Analysis Using Control Chart Limits
Process is completed (sample mean data)
160 mg/tab USL
156.4 mg/tab UCL
Grand Average
151.0 mg/tab CL
Process Capability Range
145.6 mg/tab LCL
Cpk
( 3.07−3.47e )
P=e
19
CpK vs Sigma Level
x −μ ⎛ USL − μ μ − LSL ⎞
Z= CpK = Min⎜ , ⎟
σ ⎝ 3σ 3σ ⎠
CpK = Min(Cpu,Cpl)
22
Quality Attributes Distributed in-between the Limits
μ = Process Mean
σ = Process SD
68.26%
95.46%
LSL USL
99.73%
95.46%
LSL=90 USL=110
99.73%
110 − 101.03
μ = Process Mean = 101.03 Z Min = = 2.89
σ = Process SD = 3.10 3.1
Z Min 2.89
101.03 − 90 CpK = = = 0.96
Z Max = = 3.56 3 3
3.1
68.26%
95.46%
LSL=90 USL=110
99.73%
26
Sigma Level vs CpK vs Defect Rate
Excel Function =1-NORMSDIST(1.5) = 6.68%
28
In ASEAN Guideline
29
EXAMPLE: Sigma - Getting it Right First Time.
Process shifted by 1.5σ, CpK = (6σ-1.5σ)/3σ = 1.5, Excel =1-NORMSDIST(6-1.5) = 3.4 ppm
30
Minimum Regulatory “Sigma”
Level for Drugs?
Under cGMP when failures/recalls
exceeds 10% - no longer “validated.”
The minimum regulatory "Sigma” ~ 1.65?
CP SIGMA DEFECTS COST CLASS
0.67 2) 5% 25-35% Not Capable
Pharmaceuticals Competitive
1.0 3) 0.13% 20-25% Average
1.33 4) 60 ppm 12-18% Healthy
Semiconductor
1.66 5) 1 ppm 4-8% Superior
2.0 6) 2 ppb 1-3% World Class
FDA Science Board 11/16/01: PricewaterhouseCooper Presentation
(Modified by AH)
31
How this is a Win-Win
High
6
5 6σ - World Class
4 5σ - Superior
QUALITY 4σ - Healthy
3 3σ - Average
2 2σ - Not Capable
1 1σ - Not Competitive
Low
Low High
PRODUCTIVITY
32
CpK Distribution for Product A
33
CpK Distribution for Product A
34
CpK Distribution for Product B
35
CpK Distribution for Product B
36
Retrospective PV: Assay Data (Core)
Real Case
Lot # Assay Lot # Assay Lot # Assay
1 103.06 8 99.64 15 99.60
2 99.37 9 98.30 16 97.69
3 100.60 10 101.80 17 98.24
4 99.86 11 99.27 18 99.45
5 95.94 12 97.55 19 98.69
6 100.00 13 99.89 20 97.26
7 101.74 14 102.21 – –
Mean 99.51 SD 1.79 σ 1.81
UCL 104.94 CL 99.51 LCL 94.08 37
Retrospective Process Validation:
Assay Data & CpK (Core)
38
Retrospective PV: Assay Data (Coated)
Real Case
Lot # Assay Lot # Assay Lot # Assay
1 98.55 8 102.73 15 98.95
2 97.00 9 101.10 16 96.13
3 99.14 10 101.09 17 99.45
4 102.48 11 99.86 18 101.53
5 100.44 12 99.76 19 98.88
6 100.90 13 103.24 20 99.13
7 100.07 14 101.14 – –
Mean 100.08 SD 1.80 σ 1.82
UCL 105.54 CL 100.08 LCL 94.62 39
Retrospective Process Validation:
Assay Data & CpK (Coated)
40
Retrospective PV – Dissolution Mean
(Pooled?) Data
Lot # DR Mean Lot # DR Mean Lot # DR Mean
1 96.92 8 102.25 15 100.59
2 98.98 9 98.82 16 96.31
3 94.79 10 102.77 17 99.42
4 98.43 11 103.10 18 98.75
5 98.86 12 97.70 19 101.24
6 98.42 13 100.24 20 94.39
7 101.66 14 101.53 – –
Mean 99.26 SD 2.47 σ 2.50
UCL 106.77 CL 99.26 LCL 91.75 41
Retrospective Process Validation:
Dissolution Mean (Pooled) Data & CpK
42
Retrospective PV: CU Data
Real Case
Lot # CU SD Lot # CU SD Lot # CU SD
1 3.15 8 0.56 15 1.51
2 1.67 9 2.10 16 3.68
3 2.92 10 0.97 17 3.02
4 1.38 11 2.00 18 1.58
5 1.70 12 2.32 19 2.08
6 2.39 13 3.15 20 2.12
7 4.62 14 2.15 – –
Gr. Av. 100.58 Variance* 5.95 SD* 2.44
USL 115% LA LSL 85% LA * Pooled 43
Pooled (Weighted-Average) Sample SD to
Estimate Population SD
2 2 2
S1 + S2 + .. + Sk 2
= = S =σ
k
Same
Sample Size
44
Process Capability Analysis Using Cp & CpK