quality assurance & quality control in pharma industry dr. basavaraj k. nanjwade m.pharm., ph. d...

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Assurance Assurance & & Quality Control Quality Control In Pharma In Pharma Industry Industry Dr. Basavaraj K. Nanjwade Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D M.Pharm., Ph. D Associate Professor of Pharmaceutics Associate Professor of Pharmaceutics Department of Pharmaceutics Department of Pharmaceutics KLE University, Belgaum – 590010, Karnataka, INDIA KLE University, Belgaum – 590010, Karnataka, INDIA E-mail: E-mail: [email protected] [email protected] Cell No: 00919742431000 Cell No: 00919742431000

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Page 1: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Quality AssuranceQuality Assurance && Quality Control Quality Control

In Pharma In Pharma IndustryIndustry

Dr. Basavaraj K. NanjwadeDr. Basavaraj K. Nanjwade M.Pharm., Ph. DM.Pharm., Ph. D

Associate Professor of PharmaceuticsAssociate Professor of PharmaceuticsDepartment of PharmaceuticsDepartment of Pharmaceutics

KLE University, Belgaum – 590010, Karnataka, INDIAKLE University, Belgaum – 590010, Karnataka, INDIAE-mail: E-mail: [email protected]@yahoo.co.in

Cell No: 00919742431000Cell No: 00919742431000

Page 2: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

QC

GMP

QA

Page 3: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

It is the sum total of the organized arrangements

with the objective of ensuring that products

will be of the quality required for their

intended use

QA

Page 4: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Is that part of Quality Assurance aimed at

ensuring that products are consistently

manufactured to a quality appropriate to

their intended use

GMP

Page 5: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Is that part of GMP concerned with sampling,

specification & testing, documentation & release procedures which ensure

that the necessary & relevant tests are

performed & the product is released for use only after

ascertaining it’s quality

QC

Page 6: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

QAQA and and QCQC

• QC is that part of GMP which is concerned with sampling,

specifications, testing and with in the organization, documentation,and release procedures which ensure that the necessary and relevant tests are carried out

• QA is the sum total of organized arrangements made with the object of ensuring that product will be of the Quality required by their intended use.

Page 7: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

QAQA and and QCQC

• Operational laboratory techniques and activities used to fulfill the requirement of Quality

• All those planned or systematic actions necessary to provide adequate confidence that a product will satisfy the requirements for quality

Page 8: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

QAQA and and QCQC

• QC is lab based • QA is company based

Page 9: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Determine impurity level in relevant batches1

Acceptance criterion = A or B

(as appropriate)

Isimpurity also

a degradation

product?

IsA or B

greater than thequalifiedlevel?

Acceptance criterion = qualified levelor establish new qualified level2

Estimate maximum increase in impurityat retest date using data from relevant

accelerated and long-term stability studies

Determine maximum likely level as:A + increase in degradation product at

appropriate storage conditions.(Let this = B)

YES

YES

NO

NO

ESTABLISHING ACCEPTANCE CRITERION FOR A SPECIFIED IMPURITY IN A NEW DRUG SUBSTANCE

1 Relevant batches are those from development, pilot and scale-up studies.2 Refer to ICH Guideline on Impurities in New Drug Substances

Definition: upper confidence limit = three times the standard deviation of batch analysis data

Determine mean + upper confidence

limit for the impurity (Let this = A)

Page 10: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Doesdegradation

occur during productmanufacture?

Estimate maximum increase in degradation product at shelf life using

data from relevant accelerated andlong-term stability studies.

(Let this = D)

Determine maximum likely level as drug substance acceptance criterion2.

((A or B) + C + D)

Ismaximum likely level

greaterthan thequalifiedlevel?

Estimate maximum increase in degradationproduct during manufacture from relevantbatches1. (Let this = C)

Acceptance criterion = maximum likely level.

Acceptance criterion = qualified level

or establish new qualified level3

or new storage conditionsor reduce shelf life.

NO

NO

YES

YES

ESTABLISHING ACCEPTANCE CRITERION FOR A DEGRADATION PRODUCT IN A NEW DRUG PRODUCT

1 Relevant batches are those from development, pilot and scale-up studies.2 Refer to Decision Tree 1 for information regarding A and B.3 Refer to ICH Guideline on Impurities in New Drug Products.

Page 11: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Is the drug product a soliddosage form or liquid containing undissolved

drug substance?

No drug substance particlesize acceptance criterion required for solution dosage forms.

1. Is the particle size critical to dissolution, solubility, or bioavailability?2. Is the particle size critical to drug product processability?3. Is the particle size critical to drug product stability?4. Is the particle size critical to drug product content uniformity? 5. Is particle size critical for maintaining product appearance?

Set Acceptance Criterion

No Acceptance Criterion Required

If YES to any

If NO to all

NO

YES

SETTING ACCEPTANCE CRITERIA FOR DRUG SUBSTANCE PARTICLE SIZE DISTRIBUTION

Page 12: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

INVESTIGATING THE NEED TO SET ACCEPTANCE CRITERIA FOR POLYMORPHISMIN DRUG SUBSTANCES AND DRUG PRODUCTS

Drug Substance

1.

2.

NO

YES

Conduct polymorphismscreen on drug substance. No further action

Candifferent polymorphs

be formed?

GO TO

Characterize the forms:e.g., - X-ray Powder Diffraction - DSC / Thermoanalysis - Microscopy - Spectroscopy

Page 13: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

INVESTIGATING THE NEED TO SET ACCEPTANCE CRITERIA FOR POLYMORPHISMIN DRUG SUBSTANCES AND DRUG PRODUCTS

2.

3.GO TO

NO

NO

YES

Do theforms have

different properties?(solubility, stability,

melting point)

Is drugproduct safety,performance or

efficacy affected?

No further test oracceptance criterionfor drug substance

YES

Set acceptance criterionfor polymorph content

in drug substance

Page 14: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

INVESTIGATING THE NEED TO SET ACCEPTANCE CRITERIA FOR POLYMORPHISMIN DRUG SUBSTANCES AND DRUG PRODUCTS

3.

YES

NO

NO

YES

Doesdrug product

performance testingprovide adequate control if polymorph ratio changes

(e.g., dissolution)?

Establish acceptance criteriafor the relevant performance test(s).

Monitor polymorph form duringstability of drug product.

No need to set acceptance criteriafor polymorph change in drug product.

Does achange occurwhich could

affect safety or efficacy?

Establish acceptance criteriawhich are consistent with

safety and/or efficacy.

Drug Product - Solid Dosage Form or Liquid Containing Undissolved Drug Substance

Undertake the following processes only if technically possibleto measure polymorph content in the drug product.

Page 15: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

ESTABLISHING IDENTITY, ASSAY AND ENANTIOMERIC IMPURITY PROCEDURES FOR CHIRAL NEW DRUG SUBSTANCES AND NEW DRUG PRODUCTS CONTAINING

CHIRAL DRUG SUBSTANCES

YES

AND RACEMIC

Consider the need forverifying chiral identity indrug substance release

and/or acceptance testing.

Is the newdrug substance

chiral1?

Chiral identity, assay and impurity procedures

are not needed.

YESAND ONE ENANTIOMER

Needed for drug substance specification:2 -chiral identity3

-chiral assay4

-enantiomeric impurity5

Needed for drug product specification6: -chiral assay4

-enantiomeric impurity5

NO

1 Chiral substances of natural origin are not addressed in this Guideline.

2 As with other impurities arising in and from raw materials used in drug substance synthesis, control of chiral quality could be established alternatively by applying limits to appropriate starting materials or intermediates when justified from developmental studies. This essentially will be the case when there are multiple chiral centers (e.g., three or more), or when control at a step prior to production of the final drug substance is desirable.

3 A chiral assay or an enantiomeric impurity procedure may be acceptable in lieu of a chiral identity procedure.

4 An achiral assay combined with a method for controlling the opposite enantiomer is acceptable in lieu of a chiral assay.

5 The level of the opposite enantiomer of the drug substance may be derived from chiral assay data or from a separate procedure.

6 Stereospecific testing of drug product may not be necessary if racemization has been demonstrated to be insignificant during drug product manufacture and during storage of the finished dosage form.

Page 16: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

MICROBIOLOGICAL QUALITY ATTRIBUTES OF DRUGS MICROBIOLOGICAL QUALITY ATTRIBUTES OF DRUGS SUBSTANCE AND EXCIPIENTSSUBSTANCE AND EXCIPIENTS

Is the drug substances/excipientCapable of supporting microbialGrowth or viability

Is the drug substances/excipientSterile?

Does drug substances/excipient

Synthesis/processing involveSteps which inherently

Reduce microorganisms?

Establish microbial limit acceptanceCriteria

As per the harmonized pharmacopoeialmonograph

Are monitoringMicroorganism/indicator levels

Consistently below acceptance criteriaLevels?

Test lots on a skip-lot basis forMicrobial limits and freedom fromCompendial indicator organisms.

Test each lot for microbial limits and freedom from compendial

indicator organisms.

Provide supporting data. MicrobialLimits acceptance criteria and

testingMay not be necessary

No further microbial limits testing orAcceptance criteria are necessary

Establish microbial limit acceptance criteria

As per the harmonized pharmacopeialmonograph

Does scientific evidence demonstrate thatReducation steps result in microorganism levels<acceptance criteria limits (and the absence of

Compendial indicator organisms)In the drug substance/excipient?

Provide supporting data.Microbial limits acceptace

Criteria and testingMay not be necessary

YESYES

YES

YES

YES NO

NO

NO

NO

NO

Page 17: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

1.

What type of drug release acceptance criteria are appropriate?Is the dosage

form designed to producemodified release?

YESEstablish drug release acceptance criteria.

Extended release: multiple time pointsDelayed release: two stages, parallel

or sequential

Is drug solubilityat 37 ± 0.5°C high throughoutthe physiological pH range?(Dose/ solubility < 250 mL

(pH 1.2 - 6.8))

NO

Continued on next page.

Generally single-point dissolutionacceptance criteria with a lower limitare acceptable.

Is dosage formdissolution rapid?

(Dissolution > 80% in 15 minutesat pH 1.2, 4.0, and 6.8)

Has a relationship beendetermined between disintegration

and dissolution?

Generally disintegration acceptance criteria with an upper time

limit are acceptable.YES

NO

YES

YES

NO

NO

SETTING ACCEPTANCE CRITERIA FOR DRUG PRODUCT DISSOLUTION

Page 18: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

2. What specific test conditions and acceptance criteria are appropriate? [immediate release]

Doesdissolution significantlyaffect bioavailability?

(e.g., have relevant developmentalbatches exhibited unacceptable

bioavailability?)

Attempt to develop test conditions and acceptance criteria which can distinguish batches

with unacceptable bioavailability.

YES

NO

YES

NO

YES

NO

Do changes informulation or

manufacturing variables affect dissolution?

(Use appropriate ranges.Evaluate dissolutionwithin pH 1.2 - 6.8)

Are these changes controlledby another procedure and acceptance

criterion?

Adopt appropriate test conditionsand acceptance criteria without

regard to discriminating power, topass clinically acceptable batches.

Adopt test conditions and acceptance criteriawhich can distinguish these changes.

Generally, single point acceptance criteria are acceptable.

SETTING ACCEPTANCE CRITERIA FOR DRUG PRODUCT DISSOLUTION

Page 19: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

3.

YES

NO

NO

YES

YES

NO

YES

NO

Are bioavailabilitydata available for batches

with different drug release rates?Is drug release independent of

in vitro test conditions?

Can an in vitro / in vivorelationship be established?

(Modify in vitro test conditions

if appropriate.)

Use all available stability, clinical, andbioavailability data to establish appropriate acceptance ranges.

Use the in vitro / in vivocorrelation, along with

appropriate batch data, to establish acceptance ranges.

Are acceptanceranges >20% of the

labeled content?

Provide appropriatebioavailability data

to validate theacceptance ranges.

Finalize acceptance ranges.

SETTING ACCEPTANCE CRITERIA FOR DRUG PRODUCT DISSOLUTION

What are appropriate acceptance ranges? [extended release]

Page 20: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

MICROBIOLOGICAL ATTRIBUTES OF NON-STERILE MICROBIOLOGICAL ATTRIBUTES OF NON-STERILE DRUGS PRODUCTSDRUGS PRODUCTS

Does the drug product containAntimicrobial preservatives or possess

Inherent antimicrobialactivity

Is the drug product a dry dosage form(e.g. solid oral or dry powder)?

Does scientific evidence demonstrateGrowth inhibitory properties of the

Drug product?

Microbial limits acceptance criteria and testingMay not be necessary

Establish preservative chemical acceptance criteria and Perform preservative effectiveness validation of productContaining less than or equal to the minimum specifie

Preservative concentration, or demonstrate the inherentAntimicrobial activity of the drug product.

Establish microbial limit acceptance criteriaAs per the harmonized pharmacopoeia

Monograph.

Perform microbial limits testing on aLot-by-lot basis.

Do production lots consistently meetMicrobial limits acceptance criteria?

Perform skip-lot testing for microbialLimits, or provide scientific justification for

no routine microbial limits testing.

No

No

No

No

YES

YES

YES

YES

Page 21: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

ICH Harmonised Tripartite GuidelineICH Harmonised Tripartite Guideline

• Stability Testing of New Drug Substances and Products

• Stability Testing: Photostability Testing of New Drug Substances and Products

• Stability Testing for New Dosage Forms

• Bracketing and Matrixing Designs for Stability Testing of New Drug Substances and Products

• Evaluation for Stability Data

• Stability Data Package for Registration Applications in Climatic Zones III and IV

• Validation of Analytical Procedures: Text and Methodology

• Impurities In New Drug Substances

Page 22: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

ICH Harmonised Tripartite GuidelineICH Harmonised Tripartite Guideline

• Impurities in New Drug Products

• Impurities: Guideline for Residual Solvents

• Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Microbiological Examination of Non-Sterile Products: Microbial Enumerations Tests

• Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Microbiological Examination of Non-Sterile Products: Test for Specified Micro-Organisms

Page 23: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

ICH Harmonised Tripartite GuidelineICH Harmonised Tripartite Guideline

• Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Microbiological Examination of Non-Sterile Products: Acceptance Criteria for Pharmaceutical Preparations and Substances for Pharmaceutical Use

• Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Residue on Ignition/Sulphated Ash

• Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Test for Extractable Volume of Parenteral Preparations

Page 24: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

ICH Harmonised Tripartite GuidelineICH Harmonised Tripartite Guideline

• Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Test for Particulate Contamination: Sub-Visible Particles

• Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Disintegration

• Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Uniformity of Dosage Units

• Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Region on Dissolution Test

Page 25: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

ICH Harmonised Tripartite GuidelineICH Harmonised Tripartite Guideline

• Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Sterility Test

• Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions onTablet Friability

• Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Polyacrylamide Gel Electrophoresis

• Viral Safety Evaluation of Biotechnology Products Derived from Cell Lines of Human or Animal Origin

Page 26: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

ICH Harmonised Tripartite GuidelineICH Harmonised Tripartite Guideline

• Quality of Biotechnological Products: Analysis of the Expression Construct in Cells used for Production of r-DNA Derived Protein Products

• Quality of Biotechnological Products: Stability Testing of Biotechnological/Biological Products

• Derivation and Characterisation of Cell Substrates Used for Production of Biotechnological/Biological Products

• Comparability of Biotechnological/Biological Products Subject to Changes in their Manufacturing Process

• Specifications: Test Procedures and Acceptance Criteria for New Drug Substances and New Drug Products: Chemical Substances

Page 27: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

ICH Harmonised Tripartite GuidelineICH Harmonised Tripartite Guideline

• Specifications: Test Procedures and Acceptance Criteria for Biotechnological/Biological Products

• Good Manufacturing Practice Guide for Active Pharmaceutical Ingredients

• Pharmaceutical Development

• Quality Risk Management

• Pharmaceutical Quality System

• Quality Implementation Working Group

Page 28: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Quality Assurance (QA) Management Procedure

Page 29: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

How to write Standard Operating How to write Standard Operating ProcedureProcedure

• SOP describes standard SOP format that you can use immediately for your quality procedure.

• SOP has instructions on how to write a formal operating procedure for your systems which your people can follow everyday.

Page 30: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

All Documents-Classifications, All Documents-Classifications, Definition and Approval MatrixDefinition and Approval Matrix

• In this SOP you will find all type of quality and Technical/Master file documents to build up a good quality management system for your manufacturing sites, definition of documents, their classification, approval requirements and retention requirements.

• This procedure has schematic diagrams for your understanding of how different types of documents are prepared and stored in a typical documentation.

Page 31: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Quality Documentation Management Quality Documentation Management and Change Controland Change Control

• This SOP describes how to generate new quality documents or change control of existing documents, review of quality documents, satellite file management, role of document author, approver, document control officer and satellite file administrator.

• In this SOP you will also find numbering systems of different quality documents like audit files, SOP’s, forms, manuals, training files, QA agreements, project files etc and their effective archiving system.

Page 32: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Documentation Rule for GMP Documentation Rule for GMP DocumentsDocuments

• This SOP describes the principles to be followed in GMP documents, entry of data and information, signature requirements and correction technique of incorrectly entered data or information.

Page 33: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Quality Documentation-Control, Quality Documentation-Control, Tracking and DistributionTracking and Distribution

• In this SOP you will find mainly the role of document control officer during the initiation, creation, circulation and approval of new quality related documents.

• It also describes the procedure of modification and review of existing document using a documentation database.

• Management of existing and superseded documents is also a art of this procedure.

• You will see all the forms referred during the instruction are attached at the end of the procedure.

Page 34: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Preparation, Maintenance and Preparation, Maintenance and Change Control of Master DocumentsChange Control of Master Documents

• This SOP particularly focused on the management of master file documents like specifications, control methods, raw materials, finished goods and packaging specification and test reports, formulation, stability files etc required to generate during the product registration in the market.

• This SOP gives instruction on their creation, change control, numbering system, approval requirements and maintenance in a simple master file database.

• You will see all the forms referred during the instruction are attached at the end of the procedure.

Page 35: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Deviation Report SystemDeviation Report System

• It is a regulatory requirement to capture all sorts of deviations evolves in your systems in order to maintain the continuous improvement to your processes and systems.

• This SOP describes how to categorize the deviations between production, audit, quality improvements, technical deviations, customer complaints and environmental, health and safety deviations.

• It describes the management responsibilities of initiating deviation, capture data, analysis, investigation, determination of assignable causes, generation of management report and initiatives to be taken on corrective and preventative actions.

Page 36: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Shelf Life of ProductShelf Life of Product

• This simple SOP describes the meaning of shelf life and provides on how to interpret shelf lives and storage conditions for your raw materials from the Certificate of Analysis, determining expiry date for your finished products by use of raw material date of manufacturing and their shelf lives.

Page 37: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Vendor Selection and EvaluationVendor Selection and Evaluation

• This SOP describes the procedure to be followed during the vendor assessment and vendor evaluation for purchasing of raw materials, critical and non critical packaging components, laboratory supplies, engineering supplies and imported finished goods from the vendor.

• These instructions are essential for approving prospective vendor.

Page 38: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Vendor CertificationVendor Certification

• This procedure aim to describe the process by which a vendor may be certified to supply materials or services.

• This procedure applies to vendors that supply a material or service to be used at any stage of manufacture by operations.

• Here you will get the roles of each department in the process to certify an approved vendor.

Page 39: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Product Complaint ProcedureProduct Complaint Procedure

• This procedure covers the receipt, logging, evaluation, investigation and reporting system of all complaints received from customers for the marketed products.

• This SOP contains step by step instruction to be followed in the customer complaint management like numbering of complaint, registration, evaluation of complaints, determination of assignable cause for the complaint deviation, implementation of corrective and preventive actions, trending of complaints and handling of counterfeit products.

Page 40: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Annual Product ReviewAnnual Product Review

• This procedure provides a guideline to annual product review which is required to be performed for each product produced for the commercial market to evaluate data, trends and to identify any preventative or corrective action that would lead to product quality improvements and report them to management.

Page 41: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Rework ProcedureRework Procedure

• This SOP contains the step by step instruction to be followed when the rework of an in-process or completed finished good is required.

• This SOP covers the reworks of in-process manufactured goods where new batch number is introduced for the reworked part and rework of manufactured finished good keeping the same batch number.

• This SOP also describes how to create rework protocols for each individual case.

Page 42: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Authorized PersonAuthorized Person

• This simple procedure describes the accreditation, accountabilities and responsibilities of an Authorized person, responsible for release of finished goods for sale.

Page 43: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Product Identification and Product Identification and TraceabilityTraceability

• The purpose of this SOP is to define the method used for the identification of all contributing materials that could affect product quality and to ensure their full traceability.

• Here you will find instruction on all the records and documents used for the identification and traceability of incoming raw materials and out going finished goods.

Page 44: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

AuditsAudits

• This SOP describes the process of planning, performing, reporting and follow-up of different audits for your systems like Internal Quality audit, Vendor audit, Environmental Health and Safety (EHS) audit, EHS workplace inspection, Housekeeping audit.

• This SOP also describes the process to be followed by manufacturing personnel during an audit from a Regulatory authority.

Page 45: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Example-Checklist for Batch DocumentationExample-Checklist for Batch Documentation

• This SOP describes the identification of all documentation relevant to a production process in the form of “Batch Documentation Checklists” and to ensure their collection by completion of the checklists by Authorized Persons.

• This procedure is based on an example of tablet packaging process described in the ‘Manufacturing’ category.

Page 46: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Evaluation of Batch Documentation Evaluation of Batch Documentation and Release for Saleand Release for Sale

• This procedure describes the process of collection, evaluation and record of batch related document generated during the production of a batch before an authorized person can release the batch for sale.

• This procedure is based on an example of tablet packaging process described in the ‘Manufacturing’ category.

Page 47: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

GMP TrainingGMP Training

• This SOP describes how to design and deliver GMP related training for your manufacturing staffs, training assessment design, recording of assessment and preparation of training reports.

Page 48: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

How to Write Training MaterialsHow to Write Training Materials

• This simple SOP contains instructions on how to write training materials, identification of training requirements, available resources, preparation of training aid checklists for your manufacturing staffs.

Page 49: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

House Keeping Audit ProcedureHouse Keeping Audit Procedure

• This SOP describes the requirements, checklists and reporting procedure on housekeeping audits.

• Individual checklist forms are attached at end of the procedure for different areas like process, laboratory, engineering stores, warehouses.

• This procedure also describes the handling of non-compliance found during the housekeeping audits.

Page 50: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Management and Control of Contract WorkManagement and Control of Contract Work

• The procedure describes the management and control of contract work provided by the contractors for packaging and finished products for your company as well as control of contract works done by your company on behalf of others.

Page 51: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Criteria for Sourcing of RM, Critical Criteria for Sourcing of RM, Critical Packaging Components and Imported Packaging Components and Imported

Finishing GoodsFinishing Goods

• The purpose of this SOP is to describe the process for approval of an external vendor/manufacturer supplying products to your company.

• It covers raw materials (including bulk products for subsidiaries and contract manufacturers), critical packaging components in contact with product and imported finished goods.

• The SOP also references affiliated documentation detailing the scope of active materials used and the approved manufacturers of these materials.

Page 52: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Quality Concern Investigation Quality Concern Investigation ProcessProcess

• This procedure contains instruction to be followed when conducting Investigations and to raise and assess Deviation Report when an investigation or incident Investigation occurs.

• This procedure is to be used in conjunction with SOP, which covers the approval and follow-up activities associated with a Deviation Report.

• Here you will find collection of information for an incident or a deviation, steps to be followed for a cross functional investigation, reporting and implementing of the outcomes of investigation.

Page 53: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Quality Control Laboratory Procedures

Page 54: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Retest Dating of Raw MaterialsRetest Dating of Raw Materials

• The purpose of this procedure is to describe how to run the expired stock report; to describe how to define the requirements for the retesting and assignment of storage period for active ingredients, excipients and raw materials; to instruct retesting procedure and to determine the status of a finished goods batch with a shorter shelf life.

Page 55: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Calibration Policies for Laboratory Calibration Policies for Laboratory InstrumentsInstruments

• This SOP describes the calibration polices of laboratory instruments/equipments.

• It describes labeling and security requirements of laboratory instruments/equipments.

• This SOP also describes the investigational steps to be required in the case of failed calibration

Page 56: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Archiving Laboratory DocumentationArchiving Laboratory Documentation

• This procedure describes retention and disposal procedures of laboratory documentation, general laboratory documentation system that includes handling of rejected raw material and finished product reports, finished goods certificate of analysis, finished goods register, raw material certificate of analysis, register, trend cards, procedure for long term document retention.

Page 57: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Management of Reference Management of Reference SubstancesSubstances

• This SOP describes the ordering referencing, storing, coding, use and general register maintenance of primary and impurity reference substances, primary reagent reference solutions, secondary raw material reference substance, assay testing procedure of secondary raw material reference substance, use of secondary raw material reference substance in the laboratory routine analysis, determination of expiry date and re-test date of reference substances.

Page 58: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Laboratory WorkbookLaboratory Workbook

• This SOP describes types of laboratory workbooks, general and GMP requirements of using workbooks, analytical data entry in the workbook, formatting of laboratory workbooks for routine testing, experiments and trials, workbook retention policy, instruction on data entry for incomplete experiments and additional data.

Page 59: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Creation of Certificate of AnalysisCreation of Certificate of Analysis

• The purpose of this procedure is to define the content and format of a Certificate of Analysis (C/A) and Certificate of Manufacture (C/M) and to provide guidance for issuing a Certificate of Analysis or Certificate of Manufacture and to locate the appropriate data required for this task.

Page 60: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Managing Analytical ReagentsManaging Analytical Reagents

• This procedure identifies the need for all analytical reagents and solutions prepared from the reagents, to have an assigned expiry date and storage conditions recorded on the label.

• Here you will find the procedure for purchase and management of analytical reagents and laboratory prepared reagents.

Page 61: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Laboratory Waste ManagementLaboratory Waste Management

• This simple procedure describes how to dispose off laboratory generated wastes of toxic, explosive, flammable, corrosive, oxidizing and biologically damaging natures.

Page 62: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Retention Samples-LaboratoryRetention Samples-Laboratory

• The purpose of this SOP is to describe the finished good and raw material sample retention procedures, products manufacture and/or received onsite and/or chemically tested by the laboratory.

Page 63: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Laboratory Supplier ApprovalLaboratory Supplier Approval

• In this simple SOP you will find the procedure for approving laboratory suppliers and criteria for the purchase of equipment, instrumentation, consumables, durables and glassware for the laboratory.

Page 64: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Laboratory Results-Out of Specification Laboratory Results-Out of Specification InvestigationInvestigation

• This procedure describes the actions to be taken by an analyst in the event the result of a test does not conform to raw material/components or finished products specifications for physical and chemical tests.

• An out of specification (OOS) result does not necessarily mean the batch under investigation fails and shall be rejected.

• The OOS result shall be investigated and the findings of the investigation, including re-test results shall be interpreted to evaluate the batch and reach a decision regarding release or rejection.

Page 65: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Raw Materials-Laboratory Testing Raw Materials-Laboratory Testing and Documentationand Documentation

• This SOP describes the procedure for sampling, location, pre-testing, testing and documentation of all raw materials and components subject to test, out of specification results, microbiological tests and release procedure for passed raw materials and components.

Page 66: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Finished Goods-Laboratory Testing and Finished Goods-Laboratory Testing and DocumentationDocumentation

• This SOP describes the procedure for sampling, location, pre-testing, testing and documentation of all finished products subject to test, reagents and standards to be used for analysis, management of out of specification results, microbiological tests and release procedure for passed finished goods.

Page 67: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Preparation and Maintenance of Preparation and Maintenance of Stability Protocols (Pharmaceuticals)Stability Protocols (Pharmaceuticals)

• This procedure describes the preparation and management of stability protocols for marketed products.

• This procedure is applicable to all protocols for stability studies on commercial products.

• The responsibility of the commercial Site stability manager for creating and maintaining protocols that are required for studies that came as a result of validation or process deviation.

Page 68: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

Stability and Trial Testing Procedure Stability and Trial Testing Procedure (Pharmaceuticals)(Pharmaceuticals)

• To describes the steps necessary to ensure the effective control of stability and trial testing programs of new and existing products.

• This procedure is focused on setting up of stability programs, testing, reporting, general sampling procedure for stability programs, data generation and analysis, annual maintenance of stability, new product stability procedure, procedure for in-house trials, reporting and interpretation of trials and conclusion of the trail program.

Page 69: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

REFERENCESREFERENCES• www.ich.org• www.fda.gov

Page 70: Quality Assurance & Quality Control In Pharma Industry Dr. Basavaraj K. Nanjwade M.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics

THANK YOUE-mail: E-mail: [email protected] Cell No: 00919742431000