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QbD/Valida*on	
  Applica*on	
  
         -­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐	
  
                                                                                                    	
  




 	
  	
  COMPLIANCE	
  BY	
  DESIGN	
  (CbD)	
  
  	
  

            QUALITY	
  SYSTEMS	
  BY	
  DESIGN	
  (QSbD)	
  
                             and	
  
COMPLIANCE	
  MASTER	
  PLAN	
  (CMP)	
  
                            QUALITY	
  SYSTEMS	
  MASTER	
  PLAN	
  (QSMP)	
  
                                                                                                    	
  
                                                                                                    	
  



                                                  A	
  LIFECYCLE	
  Approach	
  
                                                                  	
  
                                                                  	
  
                                                   Paul	
  L.	
  Pluta,	
  PhD	
  
                                                                  	
  
                                                                                                                                                                                                       1	
  
OUTLINE	
  /	
  OBJECTIVES	
  
1.	
  	
  Why?	
  
2.	
  	
  Quality	
  by	
  Design	
  (QbD)	
  
        –  Compliance	
  by	
  Design	
  (CbD)	
  comparison	
  
3.	
  	
  Valida@on	
  Master	
  Plan	
  (VMP)	
  
        –  Compliance	
  Master	
  Plan	
  (CMP)	
  comparison	
  
4.	
  	
  Lifecycle	
  Approach	
  
        –  Compliance	
  Lifecycle	
  comparison	
  
5.	
  	
  Implementa@on	
  
6.	
  	
  Benefits	
  and	
  Problems	
  
7.	
  	
  Discussion	
  
                                                                     2	
  
WHY	
  CbD	
  /	
  CMP	
  /	
  LIFECYCLE	
  APPROACH?	
  
Development	
  has	
  been	
  revolu@onized	
  by	
  QbD	
  -­‐-­‐	
  an	
  organized	
  
  approach	
  with	
  defined	
  objec@ves	
  and	
  steps.	
  	
  Industry	
  and	
  
  regulatory	
  have	
  strongly	
  embraced	
  and	
  supported	
  QbD.	
  
	
  



Valida@on	
  Master	
  Plans	
  (VMP)	
  are	
  successful	
  and	
  widely	
  
  accepted	
  documents	
  useful	
  to	
  industry	
  and	
  regulatory.	
  
	
  



The	
  FDA	
  Process	
  Valida@on	
  Guidance	
  has	
  introduced	
  the	
  
  lifecycle	
  approach	
  to	
  process	
  valida@on.	
  	
  
	
  


Coincident	
  with	
  growth	
  and	
  success	
  of	
  QbD	
  have	
  been	
  serious	
  
  GMP	
  compliance	
  incidents	
  (heparin,	
  glycerin,	
  Viracept,	
  J&J,	
  
  Genzyme).	
  
	
  
	
  




       Can	
  QbD,	
  VMP,	
  and	
  lifecycle	
  approaches	
  be	
  applied	
  to	
  
                               improve	
  compliance?	
  	
  	
  
                                                                                             3	
  
CbD	
  /	
  CMP	
  /	
  LIFECYCLE	
  OVERVIEW	
  
QUALITY	
  SYSTEMS	
  
   Development	
  of	
  system	
  
   –  Objec@ve	
  and	
  aYributes	
  of	
  quality	
  systems	
  
   –  Parameters	
  to	
  achieve	
  objec@ves	
  and	
  aYributes	
  
   –  Varia@on	
  affec@ng	
  parameters	
  
   –  Control	
  of	
  varia@on	
  
   Performance	
  of	
  system	
  
   –  Quality	
  system	
  performance	
  process	
  
   Maintaining	
  system	
  
   –  Maintain	
  and	
  monitor	
  quality	
  system	
  
   –  Improvement	
  projects	
  
   Documenta@on	
  
                                                                         4	
  
QUALITY	
  BY	
  DESIGN	
  
•  Target	
  product	
  profile	
  (TPP)	
  and	
  cri@cal	
  quality	
  
   aYributes	
  (CQA)	
  
•  Drug	
  substance	
  and	
  excipient	
  proper@es	
  
•  Formula@on	
  design	
  and	
  development	
  
•  Manufacturing	
  process	
  design	
  and	
  development	
  
•  Iden@fica@on	
  of	
  cri@cal	
  process	
  parameters	
  (CPP)	
  
   and	
  cri@cal	
  material	
  aYributes	
  (CMA)	
  
•  Risk	
  assessment	
  and	
  design	
  space	
  
•  Scale	
  up,	
  iden@fica@on	
  of	
  variables,	
  and	
  control	
  
   strategy	
  
	
  

Red	
  =	
  Original	
  QbD	
  
	
  
                                                                           5	
  
	
  
COMPLIANCE	
  by	
  DESIGN	
  
CbD	
  is	
  an	
  organized	
  approach	
  to	
  compliance	
  with	
  
  quality	
  systems.	
  	
  CbD	
  has	
  a	
  defined	
  structure	
  with	
  
  objec@ves	
  and	
  associated	
  content.	
  	
  CbD	
  con@nues	
  
  throughout	
  the	
  lifecycle	
  of	
  the	
  quality	
  systems.	
  
	
  


CbD	
  approaches	
  quality	
  systems	
  as	
  a	
  development	
  
      project	
  in	
  the	
  manner	
  of	
  QbD.	
  
	
  
     Can	
  compliance	
  be	
  improved	
  by	
  using	
  QbD	
  concepts?	
  
	
  

	
  
                                                                                  6	
  
COMPARISON	
  –	
  
    COMPLIANCE	
  BY	
  DESIGN	
  and	
  QUALITY	
  BY	
  DESIGN	
  
Objec@ves	
  and	
  cri@cal	
  compliance	
  aYributes	
  (CCA)	
  
      –  What	
  are	
  the	
  goals	
  of	
  each	
  quality	
  system?	
  
      –  What	
  makes	
  a	
  quality	
  system	
  successful?	
  
Cri@cal	
  compliance	
  parameters	
  (CCP)	
  
      –  What	
  factors	
  may	
  significantly	
  influence	
  the	
  success	
  of	
  the	
  quality	
  system?	
  	
  
Input	
  varia@on	
  and	
  control	
  
      –  What	
  varia@on	
  in	
  quality	
  system	
  opera@on	
  is	
  expected	
  and	
  how	
  is	
  it	
  
         controlled?	
  
Ongoing	
  maintenance	
  and	
  management	
  
      –  How	
  is	
  performance	
  monitored	
  and	
  maintained?	
  
Con@nuous	
  improvement	
  projects	
  
      –  How	
  can	
  the	
  quality	
  system	
  be	
  improved?	
  
CbD	
  approach	
  equivalent	
  to	
  QbD	
  =	
  Stage	
  1	
  process	
  valida*on	
  
Ongoing	
  maintenance	
  and	
  management	
  =	
  Stage	
  3	
  process	
  valida*on	
  
Con*nuous	
  improvements	
  expected	
  from	
  ongoing	
  monitoring.                      	
  
                                                                                                                           7	
  
VALDIATION	
  MASTER	
  PLAN	
  
Sec@ons	
  discuss	
  site	
  valida@on	
  categories	
  
              –    Valida@on	
  policy	
  
              –    Equipment	
  
              –    Facili@es	
  (HVAC)	
  
              –    U@li@es	
  
              –    Process	
  
              –    Cleaning	
  
Tables	
  with	
  document	
  references	
  (IQ,	
  OQ,	
  PQ)	
  
Valida@on	
  commitments	
  and	
  @melines	
  
Regular	
  updates	
  (quarterly?)	
  related	
  to	
  needs	
  frequency	
  
	
  


Note	
  “chapters”	
  of	
  VMP	
  
	
  


VMP	
  is	
  rou*nely	
  requested	
  by	
  regulatory	
  auditors.	
  
	
  
       	
                                                                       8	
  
COMPLIANCE	
  MASTER	
  PLAN	
  

CMP	
  is	
  an	
  organized	
  approach	
  to	
  documen@ng	
  the	
  CbD	
  
  methodology.	
  	
  CMP	
  has	
  a	
  defined	
  approach,	
  structure,	
  and	
  
  content.	
  	
  CMP	
  is	
  a	
  working	
  document	
  that	
  is	
  con@nually	
  
  maintained	
  throughout	
  the	
  quality	
  systems	
  lifecycle.	
  
	
  
	
  
	
  

Can	
  compliance	
  documenta*on	
  be	
  improved	
  by	
  use	
  of	
  VMP	
  
  concepts?	
  
       	
  




                                                                                          9	
  
COMPLIANCE	
  MASTER	
  PLAN	
  
•    Quality	
  System	
  
•    Facili@es	
  and	
  Equipment	
  System	
  
•    Materials	
  System	
  
•    Produc@on	
  System	
  
•    Packaging	
  and	
  Labeling	
  System	
  
•    Laboratory	
  Control	
  System	
  
•    Training	
  System	
  
•    Valida@on	
  System	
  
•    Product	
  Review	
  System	
  
•    Stability	
  System	
  
•    Product	
  Complaint	
  System	
  
•    Others	
  

Red	
  =	
  FDA	
  Quality	
  Systems	
  
Note	
  “chapters”	
  of	
  CMP	
  
                                                               10	
  
COMPLIANCE	
  MASTER	
  PLAN	
  

SYSTEM	
  TITLE	
  
•  System	
  and	
  subsystem	
  descrip@ons	
  
       –    Objec@ve	
  and	
  cri@cal	
  aYributes	
  
       –    Cri@cal	
  parameters	
  affec@ng	
  objec@ve	
  
       –    Input	
  variables	
  and	
  control	
  strategy	
  
       –    Ongoing	
  maintenance	
  and	
  management	
  
•  Con@nuous	
  improvement	
  project	
  status	
  
•  References	
  (includes	
  project	
  reports)	
  
	
  

                                                                   11	
  
LIFECYCLE	
  APPROACH	
  
FDA	
  Process	
  Valida*on	
  Guidance	
  (January	
  2011)	
  
	
  

Lifecycle	
  Approach	
  to	
  Process	
  Valida*on	
  
•  Stage	
  1.	
  	
  Process	
  Design	
  
       –  Includes	
  QbD,	
  PAT,	
  risk	
  management	
  

•  Stage	
  2.	
  	
  Process	
  Qualifica@on	
  
•  Stage	
  3.	
  	
  Con@nued	
  Process	
  Verifica@on	
  
	
  

Process	
  valida@on	
  always	
  ongoing	
  
Con@nuous	
  improvements	
  expected	
  


                                                                   12	
  
LIFECYCLE	
  APPROACH	
  
1.  Understanding	
  and	
  planning	
  
2.  Performance	
  
3.  Maintenance	
  and	
  monitoring	
  
      •    System	
  performance	
  
	
  
4.	
  	
  	
  Con@nuous	
  improvement	
  

    Applica*on	
  to	
  equipment,	
  computer	
  systems,	
  etc.
                                                                 	
  


                                                                        13	
  
LIFECYCLE	
  APPROACH	
  
Valida*on	
  Evolu*on	
  
	
  

1978	
  -­‐-­‐	
  CGMP	
  includes	
  Valida@on	
  
	
  



                                          VALIDATION	
  -­‐-­‐	
  Control	
  
1987	
  -­‐-­‐	
  Development	
  -­‐-­‐	
  
	
  


2008	
  à	
  2011	
  Lifecycle	
  approach	
  
Con@nuum	
  of	
  understanding	
  –	
  valida@on	
  –	
  maintenance	
  
	
  
	
  
	
  
	
  
	
  




UNDERSTANDING	
  à	
  VALIDATION	
  à	
  MAINTENANCE	
  à	
  IMPROVEMENT	
  



                                                                                14	
  
LIFECYCLE	
  APPROACH	
  
Recent	
  speakers	
  on	
  various	
  aspects	
  of	
  valida@on	
  and	
  
  qualifica@on	
  have	
  adopted	
  the	
  lifecycle	
  approach	
  to	
  their	
  
  fields.	
  
       –    Equipment	
  
       –    Facili@es	
  
       –    U@li@es	
  
       –    Cleaning	
  
       –    Computer	
  systems	
  
	
  


Can	
  compliance	
  be	
  improved	
  by	
  use	
  of	
  lifecycle	
  concepts	
  of	
  
  process	
  valida*on?	
  
Are	
  quality	
  systems	
  designed,	
  maintained,	
  and	
  monitored	
  to	
  
  yield	
  con*nuous	
  system	
  improvements?	
  
	
  
                                                                                            15	
  
LIFECYCLE	
  APPROACH	
  
ICH	
  Q10.	
  	
  Pharmaceu*cal	
  Quality	
  Systems	
  
•  Pharmaceu@cal	
  Development	
  
•  Technology	
  Transfer	
  
•  Manufacturing	
  
•  Product	
  Discon@nua@on	
  
ICH	
  Q10	
  primary	
  focus	
  	
  -­‐-­‐	
  product	
  performance	
  
	
  	
  	
  	
  throughout	
  product	
  lifecycle.	
  
	
  



CbD	
  focus	
  -­‐-­‐	
  quality	
  systems	
  performance	
  throughout	
  
  quality	
  system	
  lifecycle.	
  

                                                                             16	
  
IMPLEMENTATION	
  AND	
  EXAMPLES	
  
Overview	
  and	
  approach	
  
	
  


Material	
  System	
  
•  Mul@ple	
  subsystems	
  in	
  process	
  series	
  
•  Equivalent	
  to	
  manufacturing	
  processes	
  
	
  


Training	
  System	
  
•  One	
  system	
  serves	
  all	
  site	
  areas	
  
•  Different	
  competency	
  requirements,	
  i.e.,	
  different	
  risk	
  levels	
  
	
  


Valida*on	
  System	
  
•  One	
  system	
  serves	
  all	
  site	
  areas	
  
•  Different	
  valida@on	
  requirements,	
  	
  i.e.,	
  manufacturing	
  process	
  ,	
  cleaning	
  process,	
  
   equipment,	
  facili@es,	
  u@li@es,	
  etc.	
  
	
                                                                                                                17	
  
CbD	
  /	
  CMP	
  /	
  LIFECYCLE	
  IMPLEMENTATION	
  
1.	
  	
  Iden@fy	
  systems	
  in	
  the	
  organiza@on	
  
     –     FDA	
  systems	
  (6)	
  are	
  major	
  systems	
  
     –     Addi@on	
  “subsystems”	
  are	
  iden@fied	
  in	
  FDA	
  Quality	
  System	
  
     –     Other	
  systems	
  support	
  mul@ple	
  major	
  systems	
  
2.	
  	
  For	
  an	
  individual	
  system:	
  
     –     Iden@fy	
  complete	
  business	
  process	
  
     –     Iden@fy	
  subsec@ons	
  
     –     Iden@fy	
  objec@ves	
  ,	
  CCA,	
  CCP,	
  varia@on,	
  controls	
  for	
  all	
  subsec@ons	
  	
  
     –     Gap	
  analysis	
  of	
  subsec@ons	
  
     –     Risk	
  analysis	
  of	
  subsec@ons	
  
3.	
  	
  Con@nuous	
  improvement	
  projects	
  based	
  on	
  gap	
  analysis,	
  
           risk	
  analysis,	
  and	
  ongoing	
  monitoring	
  
4.	
  	
  Documenta@on	
  in	
  CMP	
  
5.	
  	
  Repeat	
  for	
  all	
  systems	
  based	
  on	
  risk.	
  

                                                                                                                18	
  
CbD	
  /	
  CMP	
  LIFECYCLE	
  IMPLEMENTATION	
  
    –     Iden@fy	
  complete	
  business	
  process	
  
    –     Iden@fy	
  system	
  subsec@ons	
  
    –     Iden@fy	
  objec@ves	
  and	
  CCA,	
  CCP,	
  varia@on,	
  and	
  controls	
  for	
  all	
  
          subsec@ons	
  	
  
    –     Gap	
  analysis	
  of	
  subsec@ons	
  
    –     Risk	
  analysis	
  of	
  subsec@ons	
  
    –     Ini@ate	
  improvement	
  projects	
  
    –     Documenta@on           	
  



Above	
  analysis	
  and	
  evalua*on	
  conducted	
  by	
  management,	
  
  each	
  sec*on	
  staff,	
  and	
  QA	
  -­‐-­‐	
  with	
  cross	
  func*onal	
  input	
  
   –  Staff	
  par*cipa*on	
  cri*cal	
  
   –  Cross-­‐func*onal	
  input	
  cri*cal	
  
           Ex:	
  	
  Process	
  experience,	
  incoming	
  test	
  data,	
  vendor	
  audits	
  
           Ex:	
  	
  Process	
  experience,	
  devia@ons,	
  CAPA,	
  training	
  

                                                                                                          19	
  
EXAMPLE:	
  	
  MATERIAL	
  SYSTEM	
  BUSINESS	
  PROCESS	
  
1.	
  	
  	
  Iden@fy	
  approved	
  vendors	
  to	
  source	
  incoming	
  materials	
  
        –    Vendors	
  approved	
  by	
  Vendor	
  QA	
  
2.	
  	
  	
  Receive	
  incoming	
  materials	
  
3.	
  	
  	
  Store	
  incoming	
  materials	
  –	
  quaran*ne	
  status	
  
4.	
  	
  	
  Submit	
  samples	
  for	
  tes*ng	
  
5.	
  	
  	
  Receive	
  and	
  evaluate	
  test	
  results	
  	
  
6.	
  	
  	
  Transfer	
  tested	
  materials	
  to	
  materials	
  to	
  status	
  areas	
  
        –    Approved	
  or	
  Rejected.	
  	
  	
  Materials	
  on	
  test	
  remain	
  in	
  quaran*ne	
  
7.	
  	
  	
  Dispense	
  approved	
  materials	
  to	
  manufacturing	
  and	
  packaging	
  loca*ons	
  
8.	
  	
  	
  WFI,	
  gas,	
  and	
  compressed	
  air	
  distribu*on	
  
9.	
  	
  	
  Received	
  and	
  store	
  manufactured	
  /	
  finished	
  products	
  –	
  quaran*ne	
  
               status	
  
10.	
  	
  Transfer	
  tested	
  materials	
  to	
  status	
  areas	
  
        –    Approved	
  or	
  Rejected.	
  	
  	
  Materials	
  on	
  test	
  remain	
  in	
  quaran@ne	
  
11.	
  	
  Transfer	
  approved	
  materials	
  to	
  distribu*on	
  center	
  
12.	
  	
  Ship	
  approved	
  materials	
  from	
  distribu*on	
  center	
  to	
  customer	
  
	
  
	
                                                                                                             20	
  
COMPLIANCE	
  BY	
  DESIGN	
  
             MATERIAL	
  SYSTEM	
  SUBSECTIONS	
  

Incoming	
  Materials	
  -­‐-­‐	
  Sourcing	
  
Incoming	
  Materials	
  –	
  Storage/tes*ng/disposi*on	
  
Drug	
  dispensing	
  
Water/gas/air	
  tes*ng/distribu*on	
  
Finished	
  Products	
  –	
  Storage/tes*ng/disposi*on	
  
Finished	
  Products	
  –	
  Distribu*on	
  
Finished	
  products	
  –	
  Offsite	
  distribu*on	
  
	
  
           Above	
  customized	
  to	
  site	
  organiza*on	
  
	
                                                                21	
  
COMPLIANCE	
  BY	
  DESIGN	
  -­‐-­‐	
  MATERIAL	
  SYSTEM	
  
                                      INCOMING	
  MATERIALS	
  -­‐-­‐	
  SOURCING	
  
System	
  objec*ve	
  and	
  cri*cal	
  akributes	
  
•      Obtain	
  high	
  quality	
  materials	
  	
  (API,	
  excipients,	
  commodi@es)	
  from	
  QA-­‐approved	
  vendors	
  for	
  eventual	
  
       dispensing	
  to	
  product	
  manufacturing	
  	
  
Cri*cal	
  parameters	
  affec*ng	
  objec*ve	
  
•      QA	
  audit,	
  inves@gate,	
  and	
  approve	
  material	
  suppliers	
  
•      Vendor	
  procedure,	
  process,	
  and	
  management	
  changes	
  
Input	
  variables	
  and	
  control	
  strategy	
  
•      Material	
  varia@on	
  
•      Vendor	
  outsource	
  commodity	
  items	
  
Ongoing	
  maintenance	
  and	
  management	
  
•      Approved	
  supplier	
  list	
  
•      Material	
  specifica@ons	
  
•      Material	
  test	
  data	
  monitoring	
  
•      Non-­‐conforming	
  materials	
  received	
  
Con*nuous	
  improvement	
  project	
  status	
  
1.	
  	
  Risk	
  analysis	
  of	
  incoming	
  materials.	
  	
  See	
  Appendix	
  for	
  project	
  descrip@on.	
  
2.	
  	
  Supplier	
  risk	
  evalua@on.	
  	
  See	
  Appendix	
  for	
  project	
  descrip@on.	
  	
  
Reference	
  documenta*on	
  
•      Risk	
  analysis	
  of	
  incoming	
  materials.	
  	
  J.	
  Doe,	
  1-­‐1-­‐10.	
  
•      Supplier	
  risk	
  evalua@on.	
  	
  J.	
  Smith	
  1-­‐4-­‐10	
  	
  
Appendix	
  
1.	
  	
  Project	
  Descrip@on:	
  	
  Risk	
  analysis	
  of	
  Incoming	
  Materials.	
  
2.	
  	
  Project	
  Descrip@on:	
  	
  Supplier	
  Risk	
  Evalua@on.	
  	
  
	
  
                                                                                                                                                      22	
  
COMPLIANCE	
  BY	
  DESIGN	
  -­‐-­‐	
  MATERIAL	
  SYSTEM	
  
               INCOMING	
  MATERIALS	
  –	
  STORAGE	
  /	
  TESTING	
  /	
  DISPOSITION	
  
System	
  objec*ve	
  and	
  cri*cal	
  akributes	
  
•    Storage	
  of	
  high	
  quality	
  materials	
  	
  (API,	
  excipients,	
  commodi@es)	
  prior	
  to	
  dispensing	
  to	
  
     product	
  manufacturing.	
  	
  Materials	
  stored	
  according	
  to	
  recommended	
  temperature.	
  	
  
     Materials	
  stored	
  according	
  to	
  QA	
  disposi@on	
  (Approved,	
  Quaran@ne,	
  Rejected)	
  
Cri*cal	
  parameters	
  affec*ng	
  objec*ve	
  
•    Vendor	
  storage	
  recommenda@ons	
  
•    Vendor	
  expira@on	
  date	
  recommenda@ons	
  
•    Power	
  supply	
  to	
  storage	
  areas	
  
Input	
  variables	
  and	
  control	
  strategy	
  
•    Storage	
  recommenda@ons	
  per	
  vendor	
  checklist.	
  
•    Expira@on	
  date	
  recommenda@ons	
  per	
  vendor	
  checklist.	
  
•    Alarm	
  system	
  for	
  temperature	
  limits	
  	
  	
  
Ongoing	
  maintenance	
  and	
  management	
  
•    Material	
  inventory	
  list	
  ongoing	
  
•    Facility	
  monitoring	
  system	
  
Con*nuous	
  improvement	
  project	
  status	
  
•      Refrigera@on	
  backup	
  generator	
  
Reference	
  documenta*on	
  
•    Material	
  requirements	
  
                                                                                                                                       23	
  
EXAMPLE:	
  	
  TRAINING	
  SYSTEM	
  BUSINESS	
  PROCESS	
  
Func*ons,	
  work	
  centers,	
  procedures	
  (training	
  modules),	
  and	
  personnel	
  
       Training	
  system	
  uses	
  validated	
  tracking	
  sokware	
  
       Training	
  system	
  defines	
  training	
  categories	
  
       Func@on	
  defines	
  work	
  centers	
  
       Func@on	
  assigns	
  procedures	
  to	
  work	
  centers	
  
       	
  	
  	
  	
  	
  -­‐	
  	
  Procedures	
  include	
  training	
  category	
  and	
  retraining	
  frequency	
  (risk	
  based)	
  
       	
  	
  	
  	
  	
  -­‐	
  	
  Training	
  modules	
  wriYen	
  
       	
  	
  	
  	
  	
  -­‐	
  	
  Training	
  modules	
  approved	
  
       Func@on	
  assigns	
  personnel	
  to	
  work	
  centers	
  
       Func@ons,	
  work	
  centers,	
  procedures,	
  and	
  personnel	
  entered	
  into	
  tracking	
  sokware	
  
       QA	
  approval	
  
	
  
	
  

1.	
  	
  Personnel	
  trained	
  according	
  to	
  category	
  and	
  frequency	
  
2.	
  	
  Personnel	
  training	
  comple@on	
  in	
  tracking	
  system	
  
3.	
  	
  Training	
  status	
  reported	
  by	
  sokware	
  	
  
4.	
  	
  Training	
  modules	
  evaluated	
  by	
  trainees	
  




                                                                                                                                               24	
  
TRAINING	
  CATEGORIES	
  

Company	
  informa@on	
  (general	
  news,	
  holidays)	
  
Awareness	
  of	
  common	
  procedures	
  (ethics,	
  analy@cal	
  
  methods,	
  tablet	
  machine	
  parameters)	
  –	
  read	
  and	
  
  sign	
  
Policies	
  and	
  procedures	
  –	
  (GMP)	
  -­‐-­‐	
  classroom	
  
Performance	
  (OtJ)	
  training	
  (HPLC,	
  tablet	
  machine	
  
  opera@on)	
  qualifica@on	
  
SME	
  qualifica@on	
  (expert	
  designa@on)	
  
External	
  con@nuing	
  educa@on	
  (scien@fic	
  mee@ngs)	
  
	
  
                                                                         25	
  
COMPLIANCE	
  BY	
  DESIGN	
  –	
  TRAINING	
  SYSTEM	
  
System	
  objec*ve	
  and	
  cri*cal	
  akributes	
  
•      Provide	
  effec@ve	
  training	
  to	
  site	
  personnel	
  	
  
Cri*cal	
  parameters	
  affec*ng	
  objec*ve	
  
•      Development	
  of	
  high	
  quality	
  training	
  modules	
  
•      Selec@on	
  of	
  appropriate	
  training	
  category	
  and	
  retraining	
  frequency	
  
•      Competency	
  of	
  training	
  instructors	
  
Input	
  variables	
  and	
  control	
  strategy	
  
•      Employee	
  experience	
  and	
  learning	
  mo@va@on	
  
•      Work	
  center	
  recommenda@ons	
  on	
  training	
  category	
  and	
  retraining	
  frequency	
  
Ongoing	
  maintenance	
  and	
  management	
  
•      Training	
  module	
  comple@on	
  records	
  
•      Trainee	
  evalua@ons	
  
•      Correla@on	
  of	
  training	
  modules	
  and	
  excep@on	
  events	
  	
  
Con*nuous	
  improvement	
  project	
  status	
  
1.         Risk	
  analysis	
  of	
  site	
  posi@ons.	
  	
  See	
  Appendix	
  
2.         Training	
  Module	
  X	
  development	
  
Reference	
  documenta*on	
  
•      Risk	
  analysis	
  of	
  site	
  posi@ons.	
  	
  J.	
  Jones,	
  1-­‐1-­‐10.	
  	
  
Appendix	
  
Project	
  Descrip@on:	
  	
  Risk	
  Analysis	
  of	
  Site	
  Posi@ons	
  
	
  	
  



                                                                                                              26	
  
EXAMPLE:	
  	
  VALIDATION	
  SYSTEM	
  BUSINESS	
  PROCESS	
  
1. Site functions design / develop new systems or changes
2. Site functions initiate new validations and qualifications or changes to validated
      systems.
•     New product / processes
•     New equipment, facilities, utilities
•     Other
   Sources of validation / qualification activities
•     R&D, Technical Support
•     Operations
•     Quality Assurance / Quality Control
•     Maintenance
3. Validation process /documentation written/monitored by validation group
•     Different requirements for different validation / qualification
•     Risk analysis
4. Appropriate post-validation tracking responsibility of QA
•     Product process data (APR)
•     Non-conformances and deviations; complaints, changes, others
•    Management review


                                                                                        27	
  
VALIDATION	
  CATEGORIES	
  
Process	
  valida@ons	
  
•  Manufacturing	
  
•  Cleaning	
  
•  Packaging	
  
•  Analy@cal	
  
•  Others	
  
Qualifica@ons	
  –	
  IQ,	
  OQ,	
  PQ;	
  ASTM	
  E2500	
  
•  Equipment	
  
•  Facili@es	
  
•  U@li@es	
  
•  Computer	
  systems	
  
•  Others	
  
	
                                                            28	
  
COMPLIANCE	
  BY	
  DESIGN	
  –	
  VALIDATION	
  	
  SYSTEM	
  
System	
  objec*ve	
  and	
  cri*cal	
  akributes	
  
•    Provide	
  effec@ve	
  lifecycle	
  valida@on	
  services	
  to	
  site	
  
Cri*cal	
  parameters	
  affec*ng	
  objec*ve	
  
•    Development	
  of	
  high	
  quality	
  products/processes,	
  equipment,	
  other	
  systems.	
  
•    Documenta@on	
  of	
  development	
  process	
  and	
  ac@vi@es	
  and	
  retrieval	
  of	
  documents	
  
•    High	
  quality	
  valida@on	
  documenta@on	
  
•    Post-­‐valida@on	
  monitoring	
  program	
  with	
  periodic	
  management	
  review	
  
Input	
  variables	
  and	
  control	
  strategy	
  
•    Technical	
  exper@se	
  
•    Knowledge	
  or	
  valida@on	
  requirements	
  and	
  expecta@ons	
  
•    Employee	
  training,	
  experience,	
  and	
  mo@va@on	
  
Ongoing	
  maintenance	
  and	
  management	
  
•    Iden@fica@on	
  of	
  appropriate	
  post-­‐valida@on	
  monitoring	
  
•    Management	
  review	
  program	
  
•    Change	
  control	
  awareness;	
  Change	
  control	
  program	
  within	
  related	
  areas	
  	
  
Con*nuous	
  improvement	
  project	
  status	
  
•        Iden@fica@on	
  of	
  improvement	
  projects,	
  e.g.,	
  valida@on	
  training	
  
Reference	
  documenta*on	
  
•    Valida@on	
  documenta@on	
  	
  
Appendix	
  
•    Project	
  reports	
  	
  	
  
                                                                                                                  29	
  
 
                           COMPLIANCE	
  MASTER	
  PLAN
•    Introduc@on	
  and	
  policy	
  
•    Quality	
  System	
  
•    Facili@es	
  and	
  Equipment	
  System	
  
•    Materials	
  System	
  
•    Produc@on	
  System	
  
•    Packaging	
  and	
  Labeling	
  System	
  
•    Laboratory	
  Control	
  System	
  
•    Training	
  System	
  
•    Valida@on	
  System	
  
•    Product	
  Review	
  System	
  
•    Stability	
  System	
  
•    Product	
  Complaint	
  System	
  
•    Others	
  

Each	
  system	
  with	
  subsec*ons	
  has	
  descrip*on,	
  objec*ves,	
  CQA,	
  CCP,	
  varia*on,	
  
   control	
  of	
  varia*on,	
  projects	
  completed	
  (improvements),	
  	
  commitments,	
  etc.	
  
CMP	
  available	
  to	
  auditors	
  
                                                                                                            30	
  
CbD	
  /	
  CMP	
  /	
  LIFECYCLE	
  POSITIVES	
  
•  Organized	
  and	
  comprehensive	
  focus	
  on	
  compliance	
  based	
  on	
  risk	
  to	
  
     the	
  pa@ent	
  and	
  the	
  organiza@on	
  –	
  Based	
  on	
  successful	
  concepts	
  
•  System	
  design	
  -­‐-­‐	
  Gap	
  analysis	
  
•  Risk	
  analysis	
  
•  Cross-­‐func@onal	
  systems	
  thinking	
  
•  Consistent	
  priori@zed	
  mi@ga@on	
  ac@vi@es	
  across	
  func@ons	
  –	
  based	
  
     on	
  risk	
  
•  Varia@on	
  iden@fica@on	
  and	
  control	
  strategy	
  
•  Centralized	
  tracking	
  of	
  commitments	
  
•  Con@nuous	
  improvements	
  based	
  on	
  systems	
  monitoring	
  
•  Standardized	
  audit	
  expecta@ons	
  and	
  documenta@on	
  
•  Organiza@on	
  commitment,	
  transparency,	
  and	
  credibility	
  
•  Track	
  organiza@on	
  accomplishments	
  completed	
  
•  Strong	
  message	
  to	
  employees	
  
•  Strong	
  message	
  to	
  auditors	
  
•  Poten@al	
  “credit”	
  in	
  audits	
  for	
  projects	
  completed	
  and	
  new	
  
     commitments	
  iden@fied	
  
	
                                                                                                31	
  
CPD	
  /	
  CMP	
  /	
  LIFECYCLE	
  NEGATIVES	
  
Difficult	
  	
  
•  Gepng	
  organized	
  is	
  extremely	
  difficult!	
  
•  Risk	
  analysis	
  is	
  difficult	
  
•  Gap	
  analysis	
  is	
  difficult	
  
•  Changes	
  are	
  difficult	
  
Transparency	
  
•  Being	
  open	
  about	
  gaps	
  and	
  deficiencies	
  may	
  have	
  
   regulatory	
  and	
  poli@cal	
  risks	
  
Organiza*onal	
  commitments	
  
•  Headcount	
  needed	
  to	
  correct	
  deficiencies	
  
	
  
           Do	
  the	
  benefits	
  outweigh	
  the	
  nega*ves?	
  

                                                                             32	
  
OTHER	
  THOUGHTS	
  
ASTM	
  E2500	
  
•      Addresses	
  valida@on	
  cri@cism	
  by	
  risk	
  priori@za@on	
  
•      Pfizer	
  using	
  
FDA	
  Comments	
  
•      Prosecu@on	
  of	
  responsible	
  execu@ves	
  /	
  management	
  
•      Transparency	
  
•      Generally	
  posi@ve	
  comments	
  on	
  QbD	
  -­‐-­‐	
  Concerns	
  about	
  implementa@on	
  
•      Site	
  organiza@on	
  according	
  to	
  systems	
  
	
  

ICH	
  Q10	
  	
  Pharmaceu*cal	
  Quality	
  System	
  Elements	
  
•      Process	
  performance	
  and	
  product	
  quality	
  monitoring	
  system	
  
•      CAPA	
  system	
  
•      Change	
  management	
  system	
  
•      Management	
  review	
  of	
  process	
  performance	
  and	
  product	
  quality	
  
	
  

Medical	
  Devices	
  
•      Management	
  controls	
  
•      Design	
  controls	
  
•      CAPA	
  
•      Produc@on	
  and	
  process	
  controls	
  
•      Steriliza@on	
  process	
  controls	
  
•      Sampling	
  plans	
  instruc@ons	
  
	
  
                                                                                                           33	
  
REGULATORY	
  COMMENTS	
  

US	
  and	
  Interna@onal	
  Regulatory	
  
•  Generally	
  very	
  posi@ve	
  
•  No	
  nega@ve	
  comments	
  
•  “I’d	
  be	
  blown	
  away	
  if	
  a	
  company	
  did	
  this!”	
  
•  “Wow”	
  
•  Other	
  comments	
  awaited	
  




                                                                            34	
  
GETTING	
  STARTED	
  
1.  Iden@fy	
  high	
  risk	
  areas	
  
      –    Example:	
  	
  Sourcing	
  of	
  incoming	
  materials	
  
      –    Example:	
  	
  Asep@c	
  core	
  area	
  training	
  
2.  Senior	
  management	
  discussion	
  –	
  risks	
  to	
  opera@on	
  
3.  Func@on	
  management	
  discussion	
  –	
  risks	
  to	
  opera@on	
  
4.  Iden@fy	
  recep@ve	
  individuals	
  in	
  high	
  risk	
  area	
  
5.  Training	
  of	
  appropriate	
  individuals	
  
6.  Start	
  slowly	
  
7.  Communica@on.	
  	
  Modify	
  strategy	
  as	
  needed	
  to	
  insure	
  
    success	
  
8.  Expand	
  effort	
  based	
  on	
  success	
  
9.  Expect	
  resistance	
  	
  

                                                                                  35	
  
COMPLIANCE	
  BY	
  DESIGN	
  AND	
  COMPLIANCE	
  MASTER	
  PLAN	
  
                       LIFECYCLE	
  APPROACH	
  -­‐-­‐	
  SUMMARY	
  
•    CbD	
  based	
  on	
  QbD,	
  CMP	
  based	
  on	
  VMP	
  
•    Lifecycle	
  approach	
  based	
  on	
  lifecycle	
  approach	
  to	
  process	
  valida@on	
  
      –  Design,	
  Perform,	
  Monitor	
  
•    Iden@fy	
  quality	
  systems:	
  	
  FDA,	
  Quality	
  Systems,	
  support	
  systems	
  
•    Iden@fy	
  business	
  process	
  of	
  systems	
  à	
  system	
  subsec@ons	
  
•    Iden@fy	
  objec@ves	
  and	
  CCA,	
  CCP,	
  varia@on,	
  controls,	
  gaps,	
  and	
  risks	
  
•    Con@nuous	
  improvement	
  projects	
  based	
  on	
  gap,	
  risks,	
  monitoring	
  
•    Documenta@on	
  in	
  CMP	
  
•    Posi@ves:	
  	
  Organized	
  and	
  comprehensive	
  focus	
  based	
  on	
  risk	
  to	
  the	
  pa@ent	
  and	
  
     the	
  organiza@on,	
  strong	
  message	
  to	
  employees	
  and	
  to	
  auditors,	
  “credit”	
  in	
  audits	
  
•    Nega@ves:	
  	
  Difficult,	
  transparent,	
  deficiencies	
  iden@fied	
  
•    Consistent	
  with	
  FDA	
  direc@on	
  (Process	
  Valida@on,	
  risk),	
  ASTM	
  E2500,	
  and	
  ICH	
  Q8,	
  
     Q9,	
  Q10	
  
•    Cost	
  effec@ve	
  -­‐-­‐	
  High	
  risk	
  ac@vi@es	
  emphasized	
  and	
  priori@zed	
  
•    Implementa@on	
  approach	
  



                                                                                                                        36	
  
INTERACTIVE	
  DISCUSSION	
  
Comments	
  on	
  CbD	
  
Comments	
  on	
  CMP	
  
Comments	
  on	
  Lifecycle	
  
	
  
	
  

Terminology:	
  
Compliance	
  by	
  Design	
  (CbD)	
  and	
  Compliance	
  Master	
  Plan	
  (CMP)	
  
  	
       	
          	
         	
  or	
  
Quality	
  Systems	
  by	
  Design	
  (QSbD)	
  and	
  Quality	
  Systems	
  Master	
  Plan	
  

	
  

                                                                                                  37	
  
REFERENCES	
  
Pluta,	
  Paul	
  L.	
  and	
  Richard	
  Poska.	
  	
  “Compliance	
  by	
  Deisgn	
  (CbD)	
  
   and	
  Compliance	
  Master	
  Plan	
  (CMP).	
  	
  An	
  Organized	
  Approach	
  
   to	
  Compliance.” J.	
  GXP	
  Compliance,	
  V	
  14,	
  #2,	
  Spring	
  2010.	
  	
  
Pluta,	
  Paul	
  L.,	
  Richard	
  Poska,	
  and	
  Timothy	
  J.	
  Fields.	
  	
  “Compliance	
  
   by	
  Design	
  and	
  Compliance	
  Master	
  Plan” Pharmaceu4cal	
  
   Technology,	
  V35,	
  #3,	
  March	
  2011.	
  
Nash,	
  Robert	
  A.	
  	
  “The	
  Concept	
  of	
  Establishing	
  a	
  Compliance	
  
   Master	
  Plan	
  (CMP).” J.	
  Valida4on	
  Technology,	
  V	
  12,	
  #2,	
  
   February	
  2006.	
  	
  	
  
Borkar,	
  M.M.,	
  A.A.	
  Shirwaikar,	
  and	
  P.G.	
  Shilotri.	
  	
  “Step	
  by	
  Step	
  
   Approach	
  to	
  Quality	
  System	
  Implementa@on	
  and	
  Regulatory	
  
   Compliance.” J.	
  GXP	
  Compliance,	
  V	
  9,	
  #2,	
  January	
  2005.	
  
Yu,	
  Lawrence	
  X.,	
  et.	
  al.,	
  “Quality	
  by	
  Design	
  for	
  Generic	
  Drugs.”
   PharmTech.com,	
  October	
  2,	
  2009.	
  	
  
                                                                                                 38	
  
COMMERCIAL	
  
Book	
  chapter	
  authors	
  
	
  



Pilot	
  program	
  
•  System	
  or	
  subsec@on	
  using	
  CbD	
  approach	
  
	
  



Writers	
  for	
  JVT	
  and	
  JGXP	
  
•  Sample	
  journals	
  
•  Brochure	
  with	
  example	
  papers	
  
•  New	
  features	
  and	
  ongoing	
  features	
  




                                                               39	
  
PAUL	
  L.	
  PLUTA,	
  PhD	
  
Editor-­‐in-­‐Chief	
  
•  Journal	
  of	
  Valida4on	
  Technology	
  
•  Journal	
  of	
  GXP	
  Compliance	
  

Adjunct	
  Associate	
  Professor	
  
•  University	
  of	
  Illinois	
  at	
  Chicago	
  (UIC)	
  College	
  of	
  Pharmacy,	
  Chicago,	
  IL,	
  USA	
  
Editor	
  and	
  Chapter	
  Author	
  
•  Cleaning	
  and	
  Cleaning	
  Valida4on,	
  Volume	
  1.	
  	
  Basics,	
  Expecta4ons,	
  and	
  
   Principles.	
  	
  PDA	
  and	
  Davis	
  Healthcare	
  Interna@onal	
  (DHI)	
  Publishing,	
  2009	
  
•  Cleaning	
  and	
  Cleaning	
  Valida4on,	
  Volume	
  2	
  .	
  	
  Applica4ons	
  of	
  Basics	
  and	
  
   Principles.	
  	
  PDA	
  and	
  Davis	
  Healthcare	
  Interna@onal	
  (DHI)	
  Publishing,	
  2012	
  
   (expected)	
  
Contact:	
  	
  paul.pluta@comcast.net	
  	
  



                                                                                                                  40	
  

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Compliance by Design and Compliance Master Plan

  • 1. QbD/Valida*on  Applica*on   -­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐-­‐        COMPLIANCE  BY  DESIGN  (CbD)     QUALITY  SYSTEMS  BY  DESIGN  (QSbD)   and   COMPLIANCE  MASTER  PLAN  (CMP)   QUALITY  SYSTEMS  MASTER  PLAN  (QSMP)       A  LIFECYCLE  Approach       Paul  L.  Pluta,  PhD     1  
  • 2. OUTLINE  /  OBJECTIVES   1.    Why?   2.    Quality  by  Design  (QbD)   –  Compliance  by  Design  (CbD)  comparison   3.    Valida@on  Master  Plan  (VMP)   –  Compliance  Master  Plan  (CMP)  comparison   4.    Lifecycle  Approach   –  Compliance  Lifecycle  comparison   5.    Implementa@on   6.    Benefits  and  Problems   7.    Discussion   2  
  • 3. WHY  CbD  /  CMP  /  LIFECYCLE  APPROACH?   Development  has  been  revolu@onized  by  QbD  -­‐-­‐  an  organized   approach  with  defined  objec@ves  and  steps.    Industry  and   regulatory  have  strongly  embraced  and  supported  QbD.     Valida@on  Master  Plans  (VMP)  are  successful  and  widely   accepted  documents  useful  to  industry  and  regulatory.     The  FDA  Process  Valida@on  Guidance  has  introduced  the   lifecycle  approach  to  process  valida@on.       Coincident  with  growth  and  success  of  QbD  have  been  serious   GMP  compliance  incidents  (heparin,  glycerin,  Viracept,  J&J,   Genzyme).       Can  QbD,  VMP,  and  lifecycle  approaches  be  applied  to   improve  compliance?       3  
  • 4. CbD  /  CMP  /  LIFECYCLE  OVERVIEW   QUALITY  SYSTEMS   Development  of  system   –  Objec@ve  and  aYributes  of  quality  systems   –  Parameters  to  achieve  objec@ves  and  aYributes   –  Varia@on  affec@ng  parameters   –  Control  of  varia@on   Performance  of  system   –  Quality  system  performance  process   Maintaining  system   –  Maintain  and  monitor  quality  system   –  Improvement  projects   Documenta@on   4  
  • 5. QUALITY  BY  DESIGN   •  Target  product  profile  (TPP)  and  cri@cal  quality   aYributes  (CQA)   •  Drug  substance  and  excipient  proper@es   •  Formula@on  design  and  development   •  Manufacturing  process  design  and  development   •  Iden@fica@on  of  cri@cal  process  parameters  (CPP)   and  cri@cal  material  aYributes  (CMA)   •  Risk  assessment  and  design  space   •  Scale  up,  iden@fica@on  of  variables,  and  control   strategy     Red  =  Original  QbD     5    
  • 6. COMPLIANCE  by  DESIGN   CbD  is  an  organized  approach  to  compliance  with   quality  systems.    CbD  has  a  defined  structure  with   objec@ves  and  associated  content.    CbD  con@nues   throughout  the  lifecycle  of  the  quality  systems.     CbD  approaches  quality  systems  as  a  development   project  in  the  manner  of  QbD.     Can  compliance  be  improved  by  using  QbD  concepts?       6  
  • 7. COMPARISON  –   COMPLIANCE  BY  DESIGN  and  QUALITY  BY  DESIGN   Objec@ves  and  cri@cal  compliance  aYributes  (CCA)   –  What  are  the  goals  of  each  quality  system?   –  What  makes  a  quality  system  successful?   Cri@cal  compliance  parameters  (CCP)   –  What  factors  may  significantly  influence  the  success  of  the  quality  system?     Input  varia@on  and  control   –  What  varia@on  in  quality  system  opera@on  is  expected  and  how  is  it   controlled?   Ongoing  maintenance  and  management   –  How  is  performance  monitored  and  maintained?   Con@nuous  improvement  projects   –  How  can  the  quality  system  be  improved?   CbD  approach  equivalent  to  QbD  =  Stage  1  process  valida*on   Ongoing  maintenance  and  management  =  Stage  3  process  valida*on   Con*nuous  improvements  expected  from  ongoing  monitoring.   7  
  • 8. VALDIATION  MASTER  PLAN   Sec@ons  discuss  site  valida@on  categories   –  Valida@on  policy   –  Equipment   –  Facili@es  (HVAC)   –  U@li@es   –  Process   –  Cleaning   Tables  with  document  references  (IQ,  OQ,  PQ)   Valida@on  commitments  and  @melines   Regular  updates  (quarterly?)  related  to  needs  frequency     Note  “chapters”  of  VMP     VMP  is  rou*nely  requested  by  regulatory  auditors.       8  
  • 9. COMPLIANCE  MASTER  PLAN   CMP  is  an  organized  approach  to  documen@ng  the  CbD   methodology.    CMP  has  a  defined  approach,  structure,  and   content.    CMP  is  a  working  document  that  is  con@nually   maintained  throughout  the  quality  systems  lifecycle.         Can  compliance  documenta*on  be  improved  by  use  of  VMP   concepts?     9  
  • 10. COMPLIANCE  MASTER  PLAN   •  Quality  System   •  Facili@es  and  Equipment  System   •  Materials  System   •  Produc@on  System   •  Packaging  and  Labeling  System   •  Laboratory  Control  System   •  Training  System   •  Valida@on  System   •  Product  Review  System   •  Stability  System   •  Product  Complaint  System   •  Others   Red  =  FDA  Quality  Systems   Note  “chapters”  of  CMP   10  
  • 11. COMPLIANCE  MASTER  PLAN   SYSTEM  TITLE   •  System  and  subsystem  descrip@ons   –  Objec@ve  and  cri@cal  aYributes   –  Cri@cal  parameters  affec@ng  objec@ve   –  Input  variables  and  control  strategy   –  Ongoing  maintenance  and  management   •  Con@nuous  improvement  project  status   •  References  (includes  project  reports)     11  
  • 12. LIFECYCLE  APPROACH   FDA  Process  Valida*on  Guidance  (January  2011)     Lifecycle  Approach  to  Process  Valida*on   •  Stage  1.    Process  Design   –  Includes  QbD,  PAT,  risk  management   •  Stage  2.    Process  Qualifica@on   •  Stage  3.    Con@nued  Process  Verifica@on     Process  valida@on  always  ongoing   Con@nuous  improvements  expected   12  
  • 13. LIFECYCLE  APPROACH   1.  Understanding  and  planning   2.  Performance   3.  Maintenance  and  monitoring   •  System  performance     4.      Con@nuous  improvement   Applica*on  to  equipment,  computer  systems,  etc.   13  
  • 14. LIFECYCLE  APPROACH   Valida*on  Evolu*on     1978  -­‐-­‐  CGMP  includes  Valida@on     VALIDATION  -­‐-­‐  Control   1987  -­‐-­‐  Development  -­‐-­‐     2008  à  2011  Lifecycle  approach   Con@nuum  of  understanding  –  valida@on  –  maintenance             UNDERSTANDING  à  VALIDATION  à  MAINTENANCE  à  IMPROVEMENT   14  
  • 15. LIFECYCLE  APPROACH   Recent  speakers  on  various  aspects  of  valida@on  and   qualifica@on  have  adopted  the  lifecycle  approach  to  their   fields.   –  Equipment   –  Facili@es   –  U@li@es   –  Cleaning   –  Computer  systems     Can  compliance  be  improved  by  use  of  lifecycle  concepts  of   process  valida*on?   Are  quality  systems  designed,  maintained,  and  monitored  to   yield  con*nuous  system  improvements?     15  
  • 16. LIFECYCLE  APPROACH   ICH  Q10.    Pharmaceu*cal  Quality  Systems   •  Pharmaceu@cal  Development   •  Technology  Transfer   •  Manufacturing   •  Product  Discon@nua@on   ICH  Q10  primary  focus    -­‐-­‐  product  performance          throughout  product  lifecycle.     CbD  focus  -­‐-­‐  quality  systems  performance  throughout   quality  system  lifecycle.   16  
  • 17. IMPLEMENTATION  AND  EXAMPLES   Overview  and  approach     Material  System   •  Mul@ple  subsystems  in  process  series   •  Equivalent  to  manufacturing  processes     Training  System   •  One  system  serves  all  site  areas   •  Different  competency  requirements,  i.e.,  different  risk  levels     Valida*on  System   •  One  system  serves  all  site  areas   •  Different  valida@on  requirements,    i.e.,  manufacturing  process  ,  cleaning  process,   equipment,  facili@es,  u@li@es,  etc.     17  
  • 18. CbD  /  CMP  /  LIFECYCLE  IMPLEMENTATION   1.    Iden@fy  systems  in  the  organiza@on   –  FDA  systems  (6)  are  major  systems   –  Addi@on  “subsystems”  are  iden@fied  in  FDA  Quality  System   –  Other  systems  support  mul@ple  major  systems   2.    For  an  individual  system:   –  Iden@fy  complete  business  process   –  Iden@fy  subsec@ons   –  Iden@fy  objec@ves  ,  CCA,  CCP,  varia@on,  controls  for  all  subsec@ons     –  Gap  analysis  of  subsec@ons   –  Risk  analysis  of  subsec@ons   3.    Con@nuous  improvement  projects  based  on  gap  analysis,   risk  analysis,  and  ongoing  monitoring   4.    Documenta@on  in  CMP   5.    Repeat  for  all  systems  based  on  risk.   18  
  • 19. CbD  /  CMP  LIFECYCLE  IMPLEMENTATION   –  Iden@fy  complete  business  process   –  Iden@fy  system  subsec@ons   –  Iden@fy  objec@ves  and  CCA,  CCP,  varia@on,  and  controls  for  all   subsec@ons     –  Gap  analysis  of  subsec@ons   –  Risk  analysis  of  subsec@ons   –  Ini@ate  improvement  projects   –  Documenta@on   Above  analysis  and  evalua*on  conducted  by  management,   each  sec*on  staff,  and  QA  -­‐-­‐  with  cross  func*onal  input   –  Staff  par*cipa*on  cri*cal   –  Cross-­‐func*onal  input  cri*cal   Ex:    Process  experience,  incoming  test  data,  vendor  audits   Ex:    Process  experience,  devia@ons,  CAPA,  training   19  
  • 20. EXAMPLE:    MATERIAL  SYSTEM  BUSINESS  PROCESS   1.      Iden@fy  approved  vendors  to  source  incoming  materials   –  Vendors  approved  by  Vendor  QA   2.      Receive  incoming  materials   3.      Store  incoming  materials  –  quaran*ne  status   4.      Submit  samples  for  tes*ng   5.      Receive  and  evaluate  test  results     6.      Transfer  tested  materials  to  materials  to  status  areas   –  Approved  or  Rejected.      Materials  on  test  remain  in  quaran*ne   7.      Dispense  approved  materials  to  manufacturing  and  packaging  loca*ons   8.      WFI,  gas,  and  compressed  air  distribu*on   9.      Received  and  store  manufactured  /  finished  products  –  quaran*ne   status   10.    Transfer  tested  materials  to  status  areas   –  Approved  or  Rejected.      Materials  on  test  remain  in  quaran@ne   11.    Transfer  approved  materials  to  distribu*on  center   12.    Ship  approved  materials  from  distribu*on  center  to  customer       20  
  • 21. COMPLIANCE  BY  DESIGN   MATERIAL  SYSTEM  SUBSECTIONS   Incoming  Materials  -­‐-­‐  Sourcing   Incoming  Materials  –  Storage/tes*ng/disposi*on   Drug  dispensing   Water/gas/air  tes*ng/distribu*on   Finished  Products  –  Storage/tes*ng/disposi*on   Finished  Products  –  Distribu*on   Finished  products  –  Offsite  distribu*on     Above  customized  to  site  organiza*on     21  
  • 22. COMPLIANCE  BY  DESIGN  -­‐-­‐  MATERIAL  SYSTEM   INCOMING  MATERIALS  -­‐-­‐  SOURCING   System  objec*ve  and  cri*cal  akributes   •  Obtain  high  quality  materials    (API,  excipients,  commodi@es)  from  QA-­‐approved  vendors  for  eventual   dispensing  to  product  manufacturing     Cri*cal  parameters  affec*ng  objec*ve   •  QA  audit,  inves@gate,  and  approve  material  suppliers   •  Vendor  procedure,  process,  and  management  changes   Input  variables  and  control  strategy   •  Material  varia@on   •  Vendor  outsource  commodity  items   Ongoing  maintenance  and  management   •  Approved  supplier  list   •  Material  specifica@ons   •  Material  test  data  monitoring   •  Non-­‐conforming  materials  received   Con*nuous  improvement  project  status   1.    Risk  analysis  of  incoming  materials.    See  Appendix  for  project  descrip@on.   2.    Supplier  risk  evalua@on.    See  Appendix  for  project  descrip@on.     Reference  documenta*on   •  Risk  analysis  of  incoming  materials.    J.  Doe,  1-­‐1-­‐10.   •  Supplier  risk  evalua@on.    J.  Smith  1-­‐4-­‐10     Appendix   1.    Project  Descrip@on:    Risk  analysis  of  Incoming  Materials.   2.    Project  Descrip@on:    Supplier  Risk  Evalua@on.       22  
  • 23. COMPLIANCE  BY  DESIGN  -­‐-­‐  MATERIAL  SYSTEM   INCOMING  MATERIALS  –  STORAGE  /  TESTING  /  DISPOSITION   System  objec*ve  and  cri*cal  akributes   •  Storage  of  high  quality  materials    (API,  excipients,  commodi@es)  prior  to  dispensing  to   product  manufacturing.    Materials  stored  according  to  recommended  temperature.     Materials  stored  according  to  QA  disposi@on  (Approved,  Quaran@ne,  Rejected)   Cri*cal  parameters  affec*ng  objec*ve   •  Vendor  storage  recommenda@ons   •  Vendor  expira@on  date  recommenda@ons   •  Power  supply  to  storage  areas   Input  variables  and  control  strategy   •  Storage  recommenda@ons  per  vendor  checklist.   •  Expira@on  date  recommenda@ons  per  vendor  checklist.   •  Alarm  system  for  temperature  limits       Ongoing  maintenance  and  management   •  Material  inventory  list  ongoing   •  Facility  monitoring  system   Con*nuous  improvement  project  status   •  Refrigera@on  backup  generator   Reference  documenta*on   •  Material  requirements   23  
  • 24. EXAMPLE:    TRAINING  SYSTEM  BUSINESS  PROCESS   Func*ons,  work  centers,  procedures  (training  modules),  and  personnel   Training  system  uses  validated  tracking  sokware   Training  system  defines  training  categories   Func@on  defines  work  centers   Func@on  assigns  procedures  to  work  centers            -­‐    Procedures  include  training  category  and  retraining  frequency  (risk  based)            -­‐    Training  modules  wriYen            -­‐    Training  modules  approved   Func@on  assigns  personnel  to  work  centers   Func@ons,  work  centers,  procedures,  and  personnel  entered  into  tracking  sokware   QA  approval       1.    Personnel  trained  according  to  category  and  frequency   2.    Personnel  training  comple@on  in  tracking  system   3.    Training  status  reported  by  sokware     4.    Training  modules  evaluated  by  trainees   24  
  • 25. TRAINING  CATEGORIES   Company  informa@on  (general  news,  holidays)   Awareness  of  common  procedures  (ethics,  analy@cal   methods,  tablet  machine  parameters)  –  read  and   sign   Policies  and  procedures  –  (GMP)  -­‐-­‐  classroom   Performance  (OtJ)  training  (HPLC,  tablet  machine   opera@on)  qualifica@on   SME  qualifica@on  (expert  designa@on)   External  con@nuing  educa@on  (scien@fic  mee@ngs)     25  
  • 26. COMPLIANCE  BY  DESIGN  –  TRAINING  SYSTEM   System  objec*ve  and  cri*cal  akributes   •  Provide  effec@ve  training  to  site  personnel     Cri*cal  parameters  affec*ng  objec*ve   •  Development  of  high  quality  training  modules   •  Selec@on  of  appropriate  training  category  and  retraining  frequency   •  Competency  of  training  instructors   Input  variables  and  control  strategy   •  Employee  experience  and  learning  mo@va@on   •  Work  center  recommenda@ons  on  training  category  and  retraining  frequency   Ongoing  maintenance  and  management   •  Training  module  comple@on  records   •  Trainee  evalua@ons   •  Correla@on  of  training  modules  and  excep@on  events     Con*nuous  improvement  project  status   1.  Risk  analysis  of  site  posi@ons.    See  Appendix   2.  Training  Module  X  development   Reference  documenta*on   •  Risk  analysis  of  site  posi@ons.    J.  Jones,  1-­‐1-­‐10.     Appendix   Project  Descrip@on:    Risk  Analysis  of  Site  Posi@ons       26  
  • 27. EXAMPLE:    VALIDATION  SYSTEM  BUSINESS  PROCESS   1. Site functions design / develop new systems or changes 2. Site functions initiate new validations and qualifications or changes to validated systems. •  New product / processes •  New equipment, facilities, utilities •  Other Sources of validation / qualification activities •  R&D, Technical Support •  Operations •  Quality Assurance / Quality Control •  Maintenance 3. Validation process /documentation written/monitored by validation group •  Different requirements for different validation / qualification •  Risk analysis 4. Appropriate post-validation tracking responsibility of QA •  Product process data (APR) •  Non-conformances and deviations; complaints, changes, others •  Management review 27  
  • 28. VALIDATION  CATEGORIES   Process  valida@ons   •  Manufacturing   •  Cleaning   •  Packaging   •  Analy@cal   •  Others   Qualifica@ons  –  IQ,  OQ,  PQ;  ASTM  E2500   •  Equipment   •  Facili@es   •  U@li@es   •  Computer  systems   •  Others     28  
  • 29. COMPLIANCE  BY  DESIGN  –  VALIDATION    SYSTEM   System  objec*ve  and  cri*cal  akributes   •  Provide  effec@ve  lifecycle  valida@on  services  to  site   Cri*cal  parameters  affec*ng  objec*ve   •  Development  of  high  quality  products/processes,  equipment,  other  systems.   •  Documenta@on  of  development  process  and  ac@vi@es  and  retrieval  of  documents   •  High  quality  valida@on  documenta@on   •  Post-­‐valida@on  monitoring  program  with  periodic  management  review   Input  variables  and  control  strategy   •  Technical  exper@se   •  Knowledge  or  valida@on  requirements  and  expecta@ons   •  Employee  training,  experience,  and  mo@va@on   Ongoing  maintenance  and  management   •  Iden@fica@on  of  appropriate  post-­‐valida@on  monitoring   •  Management  review  program   •  Change  control  awareness;  Change  control  program  within  related  areas     Con*nuous  improvement  project  status   •  Iden@fica@on  of  improvement  projects,  e.g.,  valida@on  training   Reference  documenta*on   •  Valida@on  documenta@on     Appendix   •  Project  reports       29  
  • 30.   COMPLIANCE  MASTER  PLAN •  Introduc@on  and  policy   •  Quality  System   •  Facili@es  and  Equipment  System   •  Materials  System   •  Produc@on  System   •  Packaging  and  Labeling  System   •  Laboratory  Control  System   •  Training  System   •  Valida@on  System   •  Product  Review  System   •  Stability  System   •  Product  Complaint  System   •  Others   Each  system  with  subsec*ons  has  descrip*on,  objec*ves,  CQA,  CCP,  varia*on,   control  of  varia*on,  projects  completed  (improvements),    commitments,  etc.   CMP  available  to  auditors   30  
  • 31. CbD  /  CMP  /  LIFECYCLE  POSITIVES   •  Organized  and  comprehensive  focus  on  compliance  based  on  risk  to   the  pa@ent  and  the  organiza@on  –  Based  on  successful  concepts   •  System  design  -­‐-­‐  Gap  analysis   •  Risk  analysis   •  Cross-­‐func@onal  systems  thinking   •  Consistent  priori@zed  mi@ga@on  ac@vi@es  across  func@ons  –  based   on  risk   •  Varia@on  iden@fica@on  and  control  strategy   •  Centralized  tracking  of  commitments   •  Con@nuous  improvements  based  on  systems  monitoring   •  Standardized  audit  expecta@ons  and  documenta@on   •  Organiza@on  commitment,  transparency,  and  credibility   •  Track  organiza@on  accomplishments  completed   •  Strong  message  to  employees   •  Strong  message  to  auditors   •  Poten@al  “credit”  in  audits  for  projects  completed  and  new   commitments  iden@fied     31  
  • 32. CPD  /  CMP  /  LIFECYCLE  NEGATIVES   Difficult     •  Gepng  organized  is  extremely  difficult!   •  Risk  analysis  is  difficult   •  Gap  analysis  is  difficult   •  Changes  are  difficult   Transparency   •  Being  open  about  gaps  and  deficiencies  may  have   regulatory  and  poli@cal  risks   Organiza*onal  commitments   •  Headcount  needed  to  correct  deficiencies     Do  the  benefits  outweigh  the  nega*ves?   32  
  • 33. OTHER  THOUGHTS   ASTM  E2500   •  Addresses  valida@on  cri@cism  by  risk  priori@za@on   •  Pfizer  using   FDA  Comments   •  Prosecu@on  of  responsible  execu@ves  /  management   •  Transparency   •  Generally  posi@ve  comments  on  QbD  -­‐-­‐  Concerns  about  implementa@on   •  Site  organiza@on  according  to  systems     ICH  Q10    Pharmaceu*cal  Quality  System  Elements   •  Process  performance  and  product  quality  monitoring  system   •  CAPA  system   •  Change  management  system   •  Management  review  of  process  performance  and  product  quality     Medical  Devices   •  Management  controls   •  Design  controls   •  CAPA   •  Produc@on  and  process  controls   •  Steriliza@on  process  controls   •  Sampling  plans  instruc@ons     33  
  • 34. REGULATORY  COMMENTS   US  and  Interna@onal  Regulatory   •  Generally  very  posi@ve   •  No  nega@ve  comments   •  “I’d  be  blown  away  if  a  company  did  this!”   •  “Wow”   •  Other  comments  awaited   34  
  • 35. GETTING  STARTED   1.  Iden@fy  high  risk  areas   –  Example:    Sourcing  of  incoming  materials   –  Example:    Asep@c  core  area  training   2.  Senior  management  discussion  –  risks  to  opera@on   3.  Func@on  management  discussion  –  risks  to  opera@on   4.  Iden@fy  recep@ve  individuals  in  high  risk  area   5.  Training  of  appropriate  individuals   6.  Start  slowly   7.  Communica@on.    Modify  strategy  as  needed  to  insure   success   8.  Expand  effort  based  on  success   9.  Expect  resistance     35  
  • 36. COMPLIANCE  BY  DESIGN  AND  COMPLIANCE  MASTER  PLAN   LIFECYCLE  APPROACH  -­‐-­‐  SUMMARY   •  CbD  based  on  QbD,  CMP  based  on  VMP   •  Lifecycle  approach  based  on  lifecycle  approach  to  process  valida@on   –  Design,  Perform,  Monitor   •  Iden@fy  quality  systems:    FDA,  Quality  Systems,  support  systems   •  Iden@fy  business  process  of  systems  à  system  subsec@ons   •  Iden@fy  objec@ves  and  CCA,  CCP,  varia@on,  controls,  gaps,  and  risks   •  Con@nuous  improvement  projects  based  on  gap,  risks,  monitoring   •  Documenta@on  in  CMP   •  Posi@ves:    Organized  and  comprehensive  focus  based  on  risk  to  the  pa@ent  and   the  organiza@on,  strong  message  to  employees  and  to  auditors,  “credit”  in  audits   •  Nega@ves:    Difficult,  transparent,  deficiencies  iden@fied   •  Consistent  with  FDA  direc@on  (Process  Valida@on,  risk),  ASTM  E2500,  and  ICH  Q8,   Q9,  Q10   •  Cost  effec@ve  -­‐-­‐  High  risk  ac@vi@es  emphasized  and  priori@zed   •  Implementa@on  approach   36  
  • 37. INTERACTIVE  DISCUSSION   Comments  on  CbD   Comments  on  CMP   Comments  on  Lifecycle       Terminology:   Compliance  by  Design  (CbD)  and  Compliance  Master  Plan  (CMP)          or   Quality  Systems  by  Design  (QSbD)  and  Quality  Systems  Master  Plan     37  
  • 38. REFERENCES   Pluta,  Paul  L.  and  Richard  Poska.    “Compliance  by  Deisgn  (CbD)   and  Compliance  Master  Plan  (CMP).    An  Organized  Approach   to  Compliance.” J.  GXP  Compliance,  V  14,  #2,  Spring  2010.     Pluta,  Paul  L.,  Richard  Poska,  and  Timothy  J.  Fields.    “Compliance   by  Design  and  Compliance  Master  Plan” Pharmaceu4cal   Technology,  V35,  #3,  March  2011.   Nash,  Robert  A.    “The  Concept  of  Establishing  a  Compliance   Master  Plan  (CMP).” J.  Valida4on  Technology,  V  12,  #2,   February  2006.       Borkar,  M.M.,  A.A.  Shirwaikar,  and  P.G.  Shilotri.    “Step  by  Step   Approach  to  Quality  System  Implementa@on  and  Regulatory   Compliance.” J.  GXP  Compliance,  V  9,  #2,  January  2005.   Yu,  Lawrence  X.,  et.  al.,  “Quality  by  Design  for  Generic  Drugs.” PharmTech.com,  October  2,  2009.     38  
  • 39. COMMERCIAL   Book  chapter  authors     Pilot  program   •  System  or  subsec@on  using  CbD  approach     Writers  for  JVT  and  JGXP   •  Sample  journals   •  Brochure  with  example  papers   •  New  features  and  ongoing  features   39  
  • 40. PAUL  L.  PLUTA,  PhD   Editor-­‐in-­‐Chief   •  Journal  of  Valida4on  Technology   •  Journal  of  GXP  Compliance   Adjunct  Associate  Professor   •  University  of  Illinois  at  Chicago  (UIC)  College  of  Pharmacy,  Chicago,  IL,  USA   Editor  and  Chapter  Author   •  Cleaning  and  Cleaning  Valida4on,  Volume  1.    Basics,  Expecta4ons,  and   Principles.    PDA  and  Davis  Healthcare  Interna@onal  (DHI)  Publishing,  2009   •  Cleaning  and  Cleaning  Valida4on,  Volume  2  .    Applica4ons  of  Basics  and   Principles.    PDA  and  Davis  Healthcare  Interna@onal  (DHI)  Publishing,  2012   (expected)   Contact:    paul.pluta@comcast.net     40