Tài liệu GMP được chia sẻ bởi GMPc Việt Nam - Nhà tư vấn Sáng tạo, Chuyên nghiệp, Toàn diện Dự án Nhà máy GMP (EU, PIC/S, WHO, ASEAN), ISO 13485:2012, ISO/IEC 17025:2005, ISO 15189:2012, ISO 15378:2011, ISO 9001:2008
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Tài liệu (phần 2) | Tài liệu GMP
1. Module 12 – part 2 | Slide 1 of 35 January 2006
Basic Principles of GMP
Documentation
Part 2
15
2. Module 12 – part 2 | Slide 2 of 35 January 2006
15.10
Documentation
Labels
What must be labelled?
Containers, equipment, premises
Label information?
Clear, unambiguous, company format
Intermediates and bulk products
Colours can be used, e.g. green (accepted), red (rejected)
3. Module 12 – part 2 | Slide 3 of 35 January 2006
Basic Principles of GMP
Different types of labels,
e.g. cleaning status,
production stage, status of
materials
Other types of labels?
4. Module 12 – part 2 | Slide 4 of 35 January 2006
Basic Principles of GMP
Labels can indicate the
status of materials such
as "quarantine"
5. Module 12 – part 2 | Slide 5 of 35 January 2006
15.11
Documentation
Finished Product Label
National legislation, but includes:
Name
Active ingredients and amounts
Batch number
Expiry date
Storage conditions, precautions if necessary
Directions for use, earnings
Name and address of manufacturer
6. Module 12 – part 2 | Slide 6 of 35 January 2006
15.12
Documentation
Reference standards
Label to include:
Name
Potency or concentration
Date of manufacture
Expiry date
Date the closure is first opened
Storage condition
Control number
7. Module 12 – part 2 | Slide 7 of 35 January 2006
15.14, 15.15
Documentation
Specifications
Specifications:
Authorized, approved, signed and dated
Starting, packaging materials and finished products: include
tests on identity, content, purity, quality
Intermediates and bulk
Water, solvents and reagents
QC, QA or documentation centre
8. Module 12 – part 2 | Slide 8 of 35 January 2006
15.13, 15.16 -15.17
Documentation
Specifications and Test Procedures
Specifications:
Periodic review
Compliance with current pharmacopoeia
Pharmacopoeia, reference standards and spectra available
Test Procedures:
Validated (facility and equipment) before routinely used
9. Module 12 – part 2 | Slide 9 of 35 January 2006
15.18 -15.19
Documentation
Specifications: Starting and packaging materials
Include:
Name (e.g. INN) and internal code
Pharmacopoeia (if applicable)
Qualitative and quantitative requirements and limits
Other data may include:
Supplier
Sampling procedure or reference
Storage conditions, precautions
Retest date
10. Module 12 – part 2 | Slide 10 of 35 January 2006
Basic Principles of GMP
What types of documents
are associated with sampling
of starting materials?
11. Module 12 – part 2 | Slide 11 of 35 January 2006
15.21
Documentation
Specifications: Finished products
Include:
Name and code reference
Names of actives (e.g. INN)
Formula
Dosage form, package details
Reference to sampling
Qualitative and quantitative requirements and limits
Storage conditions and precautions
Shelf life
12. Module 12 – part 2 | Slide 12 of 35 January 2006
15.22 – 15.23
Documentation
Master Formulae - I
Master formula for each product and batch size
Manufacturing instructions include:
Name of product with product reference code
Dosage form, strength and batch size
List of starting materials including quantities and unique
reference code
Expected final yield with acceptable limits (and intermediate
yields)
Processing location and principal equipment
13. Module 12 – part 2 | Slide 13 of 35 January 2006
15.22 – 15.23
Documentation
Master Formulae - II
Manufacturing instructions - continued
Equipment preparation (e.g. cleaning, assembling,
calibrating, etc.)
Detailed stepwise processing instructions and checks,
pre-treatments, sequence of additions, times,
temperatures, etc.
In-process control instructions and their limits
Storage requirements and special precautions
Any special precautions if needed
14. Module 12 – part 2 | Slide 14 of 35 January 2006
15.24
Documentation
Master Formulae - III
Authorized packing instructions for each product, pack size and
type, and to include:
Name of the product
Dosage form, strength and method of application
Pack size (number, weight or volume of product in final
container)
List of all packaging materials (quantities, size, types and
code number)
15. Module 12 – part 2 | Slide 15 of 35 January 2006
15.24
Documentation
Master Formulae – IV
Packing instructions - continued
Examples of printed packaging materials, with location of
batching information
Special precautions, including area clearance checks
(before and after operations)
Description of the packaging operation including equipment
to be used
In-process controls, with sampling instructions and
acceptance limits
16. Module 12 – part 2 | Slide 16 of 35 January 2006
Documentation
17. Module 12 – part 2 | Slide 17 of 35 January 2006
15.25 – 15.26
Documentation
Batch Processing Record – I
Record kept for each batch processed
Based on the master or specifications (e.g. copied to avoid
errors)
Check suitability of area and equipment
clear of previous products, documents, materials
Checks recorded
18. Module 12 – part 2 | Slide 18 of 35 January 2006
15.27
Documentation
Batch Processing Records – II
Information recorded during processing include:
Name of the product, batch number
Dates and times (e.g. start, major steps, completion)
Name of person responsible for each stage of production
Name of operators carrying out each step (check signatures)
Theoretical quantities for materials in the batch
Reference number and quantity of materials used in the batch
19. Module 12 – part 2 | Slide 19 of 35 January 2006
15.27
Documentation
Batch Processing Records – III
Main processing steps and key equipment
In-process controls carried out, person's initials, and results
obtained
Yield at each stage with comments on deviations
Expected final yield with acceptable limits
Comments on any deviations from process
Area clearance check, instructions to operators
Record of activities
20. Module 12 – part 2 | Slide 20 of 35 January 2006
Documentation
21. Module 12 – part 2 | Slide 21 of 35 January 2006
15.28, 15.29
Documentation
Batch Packaging Records – I
For every batch or part of a batch
Based on approved packaging instructions, copied or computer
generated
Before start – checks that equipment and work station suitable
and clean, no previous product
Line clearance (opening)
Recorded
22. Module 12 – part 2 | Slide 22 of 35 January 2006
15.30
Documentation
Batch Packaging Records – II
Name of the product, batch number and quantity to be packed
Batch number, theoretical quantity and actual quantity of
finished product
Actual quantity obtained – reconciliation
Dates and times of operation
Name of person responsible for packaging, initials of operators
carrying out each step
Checks, and in-process results
23. Module 12 – part 2 | Slide 23 of 35 January 2006
15.30
Documentation
Batch Packaging Records – III
Details of packaging operation, including equipment and line
used
Returns to store
Specimen of printed packaging materials, with batch coding
approval (batch number and expiry date)
Comments on deviations from the process and actions taken
and authorization
Reconciliation of packaging materials, including issues, use,
returns and destruction
24. Module 12 – part 2 | Slide 24 of 35 January 2006
Documentation
25. Module 12 – part 2 | Slide 25 of 35 January 2006
Documentation
Standard Operating Procedures (SOP) - I
What is an SOP?
Who is responsible for preparing SOPs?
What is the format for an SOP?
Which activities require SOPs?
Where should SOPs be stored?
Are SOPs associated with records?
15.31
26. Module 12 – part 2 | Slide 26 of 35 January 2006
Documentation
27. Module 12 – part 2 | Slide 27 of 35 January 2006
Documentation
Standard Operating Procedures - II
Which activities require SOPs?
Equipment and analytical apparatus:
– Assembly, validation
– Calibration
– Internal labelling, quarantine and storage of materials
– Operation
– Maintenance and cleaning
Personnel matters:
• Qualification
• Training
• Clothing
• Hygiene
15.31
28. Module 12 – part 2 | Slide 28 of 35 January 2006
Documentation
Standard Operating Procedures - III
Which activities require SOPs?
Environmental monitoring
Pest control
Complaints
Recalls
Returned goods
15.31
29. Module 12 – part 2 | Slide 29 of 35 January 2006
Documentation
Standard Operating Procedures - IV
SOP and records for receiving materials
Name of material as on delivery note
Name and in-house code
Date of receipt
Supplier's and manufacturer's name
Batch number
Quantity and number of containers received
State of container and other information
15.33
30. Module 12 – part 2 | Slide 30 of 35 January 2006
Documentation
Standard Operating Procedures - V
Other SOPs include:
Internal labelling, quarantine and storage of materials
Operation, maintenance, calibration and cleaning of all
instruments and equipment – production and QC
Sampling of materials
Batch numbering systems
Material testing at all stages of production
Complaints, recalls
15.31, 15.32
31. Module 12 – part 2 | Slide 31 of 35 January 2006
Documentation
Standard Operating Procedures - VI
Which activities require SOPs? (Continued)
Batch release or rejection
Maintenance of distribution records
Equipment assembly and validation
Maintenance, cleaning and sanitation
Personnel recruitment, training, clothing and hygiene
Environmental monitoring
Pest control
…and many more…
15.31
32. Module 12 – part 2 | Slide 32 of 35 January 2006
Documentation
Stock Control and Distribution Records
What should be recorded?
Where should records be stored?
Why are the records important?
33. Module 12 – part 2 | Slide 35 of 35 January 2006
Documentation
Group Session II
From your own experience of factory inspections, how do
documentation systems in this country compare with the WHO
model?
Identify gaps and reasons
What will help and/or hinder the process of eliminating these
gaps?
Editor's Notes
<number>
जुलाइ 28, 2014
This is part 2 of the module on Documentation.
<number>
जुलाइ 28, 2014
There are different types of documents. Let's look at "labels" as one set of documents.
What must be labelled in the factory? (Let the participants name items to be labelled and then expand on why labels are needed, what should be reflected on the labels and so on. These include labels on containers, equipment, rooms (including the product processed, stage of production, cleanliness status, "under maintenance" or "out of order").
The information appearing on labels should be clear, easily readable, and not leave any confusion. Labels should be in the company's format. Often companies prefer to have the name of the company on the label, the use of colour codes for some status, dates, signatures and other relevant information depending on what the label indicates.
<number>
जुलाइ 28, 2014
Here are some examples of labels used, including the use of colours (see "to be cleaned" in a red colour (warning), opposed to the "cleaned" label (in green).
<number>
जुलाइ 28, 2014
This is an example of a label indicating that the materials are under "quarantine" and cannot be used until released by QC. In addition, a chain is used to prevent access to the material under quarantine.
<number>
जुलाइ 28, 2014
Finished products should also be labelled. The information to appear on the label is normally prescribed in the national legislation. Normally, at least the following information should appear on the label:
Name
Active ingredients and amounts
Batch number
Expiry date
Storage conditions, precautions if necessary
Directions for use, earnings
Name and address of manufacturer
<number>
जुलाइ 28, 2014
Reference materials have very specific use in the quality control laboratory. You should also read the information in the additional guidelines for QC laboratories. Reference materials should be properly labelled to ensure the correct use and use within the prescribed requirements, conditions and date. The container should be labelled with information such as:
The Name
Potency or concentration
Date of manufacture
Expiry date
Date the closure is first opened
Storage condition
Control number
Other information could also appear on the label to ensure proper use and traceability
<number>
जुलाइ 28, 2014
Besides labels, there are also other types of documents. One specific type of document that is important to ensure quality and compliance with a quality standard, is a "specification". Different materials, components and other items may have specifications that indicate the standard to which it should comply. Think of equipment components such as filter bags, sieves, punches and dies.
Materials including starting materials, packaging materials, intermediates and bulk should also have specifications. These materials should eb tested for compliance against the specifications. All specifications should be authorized (that means approved by responsible persons, signed and dated) before use.
Specifications are normally prepared and kept, maintained (reviewed and updated) by QC or QA and are stored in the documentation centre.
<number>
जुलाइ 28, 2014
Specifications should be reviewed at regular intervals to ensure that these are current. The company should ensure, that where appropriate, the specifications are in compliance with the recommendations in current or latest pharmacopoeia.
Test procedures must be validated or verified for the available facilities before they are used for routine testing. Compendial methods need to be verified. This means that the method is demonstrated to give correct results in the laboratory facilities available. Specifications will include tests for identity, content purity and quality. Specifications should be dated and authorized. The responsibility for their issue and maintenance rests with the QC department. It may be necessary to update the documents occasionally in line with national compendiums or the company's requirements. Written specifications are required for all starting and packaging materials including water in all its various standards. The minimum requirements for these documents are:
INN name and internal code reference
Reference to pharmacopoeia monograph if appropriate
Test parameters and acceptance criteria
Other information may include:
Details of supply, testing methodology and storage conditions.
For packaging materials, there should be reference to compatibility with the drug. For all materials, the frequency of retest should be specified. If intermediates or bulk products are either purchased or dispatched, then they will need a specification. One will also be required if the data obtained from these materials are going to be used in the assessment of the finished product. They will be similar to the specification for the starting material or finished product, as appropriate. For finished products, the specification should include the following information:
Name and internal code reference
Name of the active ingredients
The formula (or a reference to it)
Description of dosage form and packaging
Sampling and testing methodology
Test parameters and acceptance criteria
Storage conditions
Shelf-life.
Specifications and test procedures will be used by the QC department and are generally located in the laboratories.
<number>
जुलाइ 28, 2014
There are specific recommendations in GMP as to what should be included in specifications. In general, the documents should be properly designed to contain the relevant information. Starting and packaging material specifications should include information such as:
Name (e.g. INN) and internal code
Pharmacopoeia (if applicable) reference
Qualitative and quantitative requirements and limits
Other data may include:
Supplier name and address
Sampling procedure or reference e.g. to the SOP
Storage conditions,
Precautions (e.g. to be observed during storage or sampling)
A Re-test date
<number>
जुलाइ 28, 2014
Let the participants list some documents associated with sampling of starting materials. These may include:
SOP for sampling
Checklist
Labels (under test, sample label. "sampled" label).
Cleanliness status label of sampling utensils
SOP for cleaning
etc
<number>
जुलाइ 28, 2014
Specifications for finished products should include:
Name and code reference for the product
Names of actives (e.g. INN)
Formula
Dosage form, package details
Reference to sampling
Qualitative and quantitative requirements and limits
Storage conditions and precautions
Shelf life
<number>
जुलाइ 28, 2014
There must be a formally approved master formula for each product that is manufactured, in each batch size. The information that it should contain includes the following:
Name of the product with product reference code
Dosage form, strength and batch size
A full list of materials including quantities and unique reference code for each
Expected final yield with acceptable limits (plus intermediate yields)
Processing location and principle equipment
<number>
जुलाइ 28, 2014
There must be a formally approved master formula for each product that is manufactured, in each batch size. The information that it should contain includes the following:
Methodology for equipment preparation (cleaning, calibration, etc......)
Stepwise processing instructions (space for operator to sign, check signature, recording of times, quantities, temperatures, etc......)
Details of in-process controls with instructions for sampling and acceptance limits
Storage requirements and any special precautions.
<number>
जुलाइ 28, 2014
The packaging instruction is the similar to the master formula, but covers packaging rather than manufacturing. There should be one document for each product and pack size. The information that it should contain includes:
Name of the product
Dosage form, strength and method of administration
Pack size (number, weight or volume of product in finished pack)
List of all packaging materials (quantities, size and code number).
(Continued on next slide)
<number>
जुलाइ 28, 2014
The packaging instruction - continued:
Examples of printed packaging materials, with location of batching information
Special precautions, including area clearance checks
Description of the packaging operation
In-process control checks, with sampling instructions and acceptance criteria.
Both these documents are used as references in the development of processing records. They should be located in development, quality control and production departments. The master formula is frequently used as the master batch-processing document. It is often photocopied to provide the individual batch-processing document. Whatever method is used, it must ensure that there can be no transcription error. The batch-processing document is never a hand-written copy. The same method can be used to prepare the batch packaging document.
<number>
जुलाइ 28, 2014
This is an example of a batch manufacturing instruction sheet.
<number>
जुलाइ 28, 2014
A batch processing record is required for each batch of material produced. The review of this document is a critical part of the batch release process. A master document should be prepared for each batch size that will be manufactured. It will be taken from the relevant parts of the master formula as discussed previously.
The first step in this document must be the area clearance check. This is a record of the previous product and batch processed in the area and a confirmation that all the material and documentation relating to that batch has been removed. It is also confirmation that all the cleaning has been carried out correctly. This check must always be documented.
The batch processing record is both a detailed instruction to the operator of the activities that must be carried out during manufacturing and a record that these activities have been carried out. It should be filled in at the time that processing takes place. Critical activities require a check signature from a second person (either from production or QC as appropriate) to confirm that the information recorded is accurate.
<number>
जुलाइ 28, 2014
The information required in the batch processing record includes:
Name of the product
Batch number
Dates and times for major steps in the process
Name of person responsible for each stage of production
Name of operators carrying out each step and check signatures if required
Theoretical quantities for materials in the batch
Reference number and quantity of materials used in the batch
<number>
जुलाइ 28, 2014
A batch processing record (continued):
The information required in the batch processing record includes:
Main processing steps and key equipment
In-process controls carried out, and the results obtained
Yield at each stage with comments on deviations
Expected final yield with acceptable limits
Comments on any deviations from the process
Area clearance check, instructions to operators
Record of activities
Information that does not change, such as the product name, process steps and theoretical quantities of material, can be printed on the master copy. Variables, such as actual quantities of materials used and yields are entered by the operators during the manufacturing process.
<number>
जुलाइ 28, 2014
This is an example of a batch record.
The elements to look for here are easy reading, by careful setting out blocks of information so that the reader is able to go through the complicated information easily, and a systematic approach to the sequence of information.
<number>
जुलाइ 28, 2014
The batch packaging record is required for every batch or part batch that is packaged. It is developed from the relevant part of the packaging instructions and, once again, its review is an important part of the batch release process. Depending on company practice and the design of the document, it may be specific to a particular batch size or may be used for a variety of sizes.
Before the start of the packaging process – checks that equipment and work station are suitable and clean should be provided. It should be checked that there is no previous product that remained on the packaging line. A formal line clearance (opening) should be done in accordance with an SOP and this should be recorded in the BPR or checklist.
<number>
जुलाइ 28, 2014
The batch packaging record.
The information required for the completed batch packaging record, once again, consists of a combination of pre-printed material and data that are added by the operators during the process:
Name of the product, batch number and quantity to be packed
Batch number, theoretical quantity and actual quantity of finished product
Reconciliation calculations
Dates and times of operation
Name of person responsible for packaging
Initials of operators carrying out each step
Checks made and results obtained
<number>
जुलाइ 28, 2014
The batch packaging record - continued:
Details of packaging operation, including equipment and line used
Returns to store
Specimen of printed packaging materials, with batch coding
Comments on deviations from the process and actions taken
Reconciliation of packaging materials, including returns and destruction.
If returns to the stores are permitted for printed packaging materials, they should first be checked to make sure that they have not been batch coded. A QC signature is required as part of this process, either on leaving the packing hall or on being received in the stores. If excess materials are destroyed, there must be a record of the quantities on the batch documentation. There should also be a procedure covering destruction, including methods and responsibilities. Reconciliation is of vital importance since it helps to confirm that the batch has been processed correctly. Any significant variation in materials should be taken as an indication that there could be a problem. Inspectors should check for investigation of these variations before the batch is signed off.
Finally, area clearance checks should show no foreign materials are carried over from one operation to the next.
<number>
जुलाइ 28, 2014
Batch packaging document and line clearance
Discuss the SOP, checklist, checks for the correct batch number and expiry date, correct printed packaging material, correct primary and secondary packaging material
<number>
जुलाइ 28, 2014
Although useful reference documents for inspectors, Standard Operating Procedures (SOPs) are written for the benefit of the persons carrying out the operation in question. They should be written so that the user can easily understand them. If possible, they should be written by or with the operators, to ensure that they accurately reflect what happens in practice. They will be written by the department responsible for carrying them out, but should also be approved by the QA department, if appropriate.
Master copies of procedures should be stored by the responsible department or centralized in the document control department. Authorized copies of each procedure should be stored adjacent to the place where the operation will be carried out, as a reference document that can be consulted at will. All critical equipment should have logbooks in which maintenance and cleaning are recorded. A record should also be kept of the use of this equipment. The procedures for sanitation should include methods, equipment, materials, responsibilities and the schedule for carrying them out.
<number>
जुलाइ 28, 2014
This is an example of an SOP sheet.
Elements to look for are the set out (all upper case can be difficult to read), accountability of the document, traceability, purpose, scope and instructions in the imperative.
<number>
जुलाइ 28, 2014
SOPs are required for a whole range of activities within the facility and may include the following:
Receipt of all material deliveries
Internal labelling, quarantine and storage of materials
Operation, maintenance and cleaning of all instruments and equipment
Sampling of materials
Batch numbering systems
Material testing at all stages of production
<number>
जुलाइ 28, 2014
Other SOPs include:
Environmental monitoring
Pest control
Complaints
Recalls
Returned goods
<number>
जुलाइ 28, 2014
The SOP for receiving material is an important SOP. The company should ensure that the correct materials are received from the correct supplier and manufacturer, the correct quantity and other relative quality parameters. The SOP and records for receiving materials should reflect at least:
Name of material as on delivery note
Name and in-house code
Date of receipt
Supplier's and manufacturer's name
Batch number
Quantity and number of containers received
State of container and other information
<number>
जुलाइ 28, 2014
To ensure that activities are performed in an organized, and consistent manner, procedures can help to ensure that an operation is carried out in a standardized manner. SOPs are used to train people, and if different people follow the same SOP in a consistent manner, then there can be a level of assurance that the process or activity will be done in a standardized manner. Therefore SOPs for most (if not all) activities are recommended.
Other SOPs include:
Internal labelling, quarantine and storage of materials
Operation, maintenance, calibration and cleaning of all instruments and equipment – production and QC
Sampling of materials
Batch numbering systems
Material testing at all stages of production
<number>
जुलाइ 28, 2014
Batch release or rejection.
Maintenance of distribution records
Equipment assembly and validation
Calibration and operation of analytical apparatus
Maintenance, cleaning and sanitation
Personnel recruitment, training, clothing and hygiene
Environmental monitoring
Pest control
Additionally, deviation and fault analysis and investigation procedures for out-of-specification results are very significant.
For further details on SOP requirements, refer to the WHO GMP text.
<number>
जुलाइ 28, 2014
Other documents can include stock control records (bin cards, registers, log books) that assist in materials management; distribution records and manuals (e.g. equipment and instrument manuals, and a water quality manual). Although not specifically listed, the need for these documents is implied in the lists of requirements under QA, GMP and QC.
The first two documents remind us that the need to record everything that a company does including the management of materials and products (from the warehouse (materials) to the production floor and continues after the finished product is sent to the warehouse, for distribution (link the traceability issue with recalls here).
Stock control documentation is required for raw materials, packaging materials and finished products. The records include batch numbers, status, quantities and expiry date. They may be manual or electronic, but must take into account the status of the batch in question. They ensure an appropriate system of material rotation, such as FIFO (first in, first out) or EEFO (earliest to expire, first out). The records will be validated by the physical stock check carried out periodically in the warehouse.
For distribution, there should be a record (e.g. per batch) of material or product. It should contain the batch number, quantity and destination of each delivery. This means that, in the case of a product recall, the information on distribution can be obtained rapidly from a single source. Using copy invoices as distribution records is not advisable unless the batch number is recorded. If a computer-controlled stock management system is used, this can provide a very acceptable method of recording distribution.
<number>
जुलाइ 28, 2014
Group session
We are now going to have our first group task which is to build a small toy of building bricks, first with no documentation and then with some very simple documentation. We will then measure the improvement that even simple documents can bring to a process.
(Depending on the participants’ ability and experience there is an alternative Group session at the end of this module.)
<number>
जुलाइ 28, 2014
Part 1 - Trainer’s Notes (use overhead)
Time required: Allow 1 hour or a little longer
Materials required: One per team of a 30-50 piece kit for building toy models from bricks, such as a racing car or truck. The Lego® brand of product or equivalent is ideal. The 50 piece models may be too complicated to allow teams to complete the building required within the short space of time you will give them. Avoid helicopters, boats and other complicated models. Make sure the model comes with building instructions using only illustrations – no text. The group session also demonstrates the power of illustration when trying to describe complicated items (such as the different sorts of blocks) and the sequence of assembly. The analogy is that illustration (photographs or drawings) or flow charts in standard operating procedures are a very powerful means of communication.
Instructions:
Prior to the group session, put all the blocks for the models into one clear plastic bag per model. Label with e.g. “Racing Car”. Provide no other information on the bag. Keep the assembly instructions and the box separately.
Form the groups into teams of about 5-6. Lower numbers than this is satisfactory but do not go above 6. A maximum of about 4 teams seems to work best. The teams will be naturally competitive but do not let this get out of hand – rather make it as fun as possible. Before handing out the plastic bags of blocks, instruct the teams not to open the bags until instructed to do so. Explain that they are to assembly a model toy with no training and no operating instructions. Compare this with a pharmaceutical factory which asks an untrained employee to clean a complicated piece of machinery with no instructions.
Score the teams efforts using the specifications and score card attached. Make this into an overhead and write on it with White Board marker to allow the O/head to be used again. You will be the sole judge awarding the points but this can be made fun, especially the aesthetic test and the robustness test. The teams will then have the manufacturer’s instructions given to them together with the box the model came in. Explain that even an illustration on a box conveys a powerful message.
Tell them you will allow them exactly one minute to look at the bags, then on the command “Start” they can have 3 Minutes exactly (for a 30 piece model) to assembly the model without any operating procedures. Allow 4-5 minutes for more complicated 50 piece kits. Monitor the time closely.
At the end of the time say Stop and warn the teams you will deduct points if any pieces are touched after the time is up. Score the results in front of everyone. Award a small prize if appropriate to the winning team. Total all points to check for improvement in the next phase. Get the teams to pull the model apart, hand out the model assembly instructions provided by the manufacturer and repeat the construction. Give exactly the same time as before. Repeat the scoring and calculate the grand total and improvement. Improvements typically range from
+50 - +100 %
<number>
जुलाइ 28, 2014
We are now going to have a group discussion. Use your own experience from inspection visits that you have made to draw up a picture of the documentation systems that are in place in most companies in this country (Alternative text if training inexperienced persons). List the main gaps that you are likely to find and try to identify the reasons for them.
When you have done that, discuss the process of eliminating those gaps. What will help companies to eliminate the gaps and what will hinder them?
Finally, what sort of responses will you insist on companies achieving when you visit them in the future and find problems.