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Importance of Documentation in
          GMP compliance
  By:
  J.Ramniwas
  Director-Regulatory and Quality Affairs
  Pharmaocean,Vadodara(India)

                                            1
Objective


•      To review general requirements for documents

•      To review specific requirements for each document

•      To give general guidance how to create good documentation system


    •A reliable evidence for GMP compliance.
    •Quality by design is the only solution to overcome the quality-related complaints in an
    organisation.
    •An essential element of quality assurance is good documentation practices.
    •The system of documentation devised or adopted should have as its main objective to
    establish, monitor, and record “quality” for all aspects of the production, quality control
    and quality assurance



                                                                                                  2
Purpose of Documentation

Clearly written documentation prevents errors that may arise in or
al or casually written communication
It provides assurance that quality related activities are carried out
exactly the way they have been planned and approved
The achievement of conformity and quality improvement
Purpose of documentation :
     To ensure that there are specifications for all materials and m
     ethods of manufacture and control
     Employees know what to do
     Responsibilities and authorities are identified
     Ensure that authorized persons have all information necessary
     for release
     Provide audit trail
     Forms the basis for improvement.
                                                                        3
Quality Based Documentation System


Corporate Communication tool – internal and external

Integral part of corporate interactions

Corporate Policies – Rationale for responsible decision making

Currency of corporation




                                                                 4
Quality Policy and its Importance


Management commitment to quality
•Customer Focused
Satisfy our customers' needs and expectations
•Make commitments we fully understand and believe we can meet
•Meet all commitments to customers on time

Performance Driven
1.       Verify that our products and services meet agreed requirements
2.Monitor, benchmark and continuously improve our business, products
         and services, organization and employees' performance

Achieve Organisation's Mission and Goals
1. Sustain and develop business growth and Intellectual Property



                                                                          5
Quality Manual

The strategic document that outlines the organization’s system of
providing quality assurance to achieve customer satisfaction
  Objectives :
    Describe the quality system structure
    Declare the quality policy and organization goal
    Describe how the organization meets the quality goal
   Content of quality manual :
      The quality policy declaration
      The goal of quality;
      The organisational structure including responsibility and aut
      hority of each key personnel
      Procedures, instructions and resources for implementing the
      quality management.
                            User :
          All personnel in the organization
          Another parties, auditors, and customers

                                                                      6
Design of Documents


Useful

Flexible

Grow

Change




                               7
Type of GMP Documents


1. Description Documents
•   Describe how to perform certain tasks
•   E.g.. SOPs, Protocols, Specifications, Master Production Records etc.
2. Data Collection Documents
•   Facilitate the timely and accurate documentation of tasks and events
•   E.g. Forms, Reports, Production Batch Records , Logbooks etc.
3. Numbering Systems
•   Serves to account for and track information and documents
•   E.g. Lot numbers, Part numbers, equipment numbers, Form numbers, SOP
    numbers, Receiving codes etc.
4. Data Files
•   Serves to organize the data in to useful categories for review and to support
    accountability and traceability requirements
•   E.g. Specification Files, Equipment Files, Equipment history files, Product files,
    Facility Qualification files etc.

                                                       J.Ramniwas                        8
Function of GMP Documents


•   Establish, monitor and document Quality
1. Description Documents
    Define and establish the Quality of Raw materials, environment, production process
    and Finished Product
2. Data Collection Documents
    Confirm the materials ,environment , production processes or product routinely meet
    the established Quality characteristics.
3. Numbering Systems
    Control and track the use of descriptive documents and data collection documents
4. Data Files
    Organize the data in to useful categories to facilitate review and retrieval




                                                                                          9
Users


1. Bottom –up
•   Manufacturing, Laboratory or Operational personnel who interact with the detailed
    steps of the system on a daily basis
•   Need to know what to do and how to do it
2. Top-Down
•   Administrative personnel e.g. management, regulatory, development, finance,
    marketing who must understand and interact with the system by reference
•   A good document is written both to inform and to educate
•   It must meet the needs of the line workers and the administrators
    E.g. SOP on specification writing- describes the purpose of specifications, provide
    guidance on the decision making associated with writing specifications, numbering
    systems, change controls and responsible personnel, steps on generating and
    approving an SOP etc.




                                                                                          10
A Well Designed Documentation
               System

Ensure Quality standards are met routinely

Minimize the potential for Error

Reduce downtime when deviations or failures occur by providing
immediate access to well organized data

Serve as a consistent training tool for line workers and administrators

GMP documents should be prepared, reviewed, approved, distributed
and archived according to written procedures.

A Poorly Designed System is a burden to all!
A simple system is always the most difficult to design.

                                                J.Ramniwas                11
Manufacturer's Role


Comply with GMP regulations

Provide Quality medications to patients
Provide documentation to support the quality of the products
from development to market and to product discontinuation

Producing documents is also part of the production




                                                               12
Principles of Good Documentation


 The heart of GMP is the establishment of well written procedures for each
 step of our quality operations

 Documentation is used for full traceability of events – cross reference all
 related documents – audit

 Written procedures provide the controls necessary to minimize the changes,
 mix-ups and errors

 Ensure compliance with GMP regulations but more importantly, we ensure
 the consistent Quality of our products.




                                                                               13
Proof of Quality


•   As a pharmaceutical company, your proof of success is found in the
    documents records that you keep.

•   Documentation is your proof that your products/ services are produced in
    compliance with the GMP regulations and your company’s operating
    procedures and standards.
•   Key Documents : Development Records, Clinical Trial Records, process
    and method validation, production batch records, OOS, Deviations,
    Investigations,   Equipment Calibration and preventive maintenance,
    Training Records, CAPA, Complaints, Change Control etc..




                                                                               14
Who Reads your Documents


    Internal
•   Colleagues
•   Supervisors and managers
•   Data Reviewers
•   QA
•   Global Network Colleagues
    External
•   Regulators – Local and Foreign
•   Customers – Local and Foreign
•   Lawyers
•   General Public
Write documents as though you are writing history.
Write for future viewers


                                                     15
Basics of Record Keeping


•   Where your signature is required, write your name legibly and in
    ink – always use include the date of signing.
•   Always document as soon as a task is performed
•   For all critical steps, a second person is required to verify the
    entered data
•   Do not document someone else’s work unless you are
    designated to do so.
•   Do not assume work has been properly documented without
    seeing the work and / or the documents, e.g. blame for
    fraudulent action




                                                                        16
Real Time Formats and Dates


•   Data entered directly as it occurs
•   Scratch paper or sticky notes must not be used
•   Records are signed and dated on the day (and time) the work
    was performed
•   Consistent date format is important for a company e.g.
    day/month/year or year/month/day
     • Alpha-numeric dating is preferred
     • 01 Nov 2008 is preferred over 01-11-2008
     • Each page should have the current date(s) – no back dating.




                                                                     17
Calculation and Numbers


Write down the formula and perform one sample calculation.

No calculation is required for simple math

e.g. 1+4 =5

Prevent using down arrow or ditto marks to show repetitiveness
e.g.




                                                                 18
Corrections

No over written
No use of white fluid
No           out
Critical corrections or omissions must be addressed and signed
by management on raw data record
Data on damaged pages should be re-entered for clarity, initial,
date and explanation
All corrections must be initiated and dated by the analyst and
reviewer when applikable
                applicable
                      John 01 Nov.2008
                                                                   19
Documentation Practices

Documentation requires that record, sign and date every step of
the operations that we perform e.g. production batch records
Documentation should always be done promptly, accurately,
legibly and in accord with our written procedures e.g. lab
notebooks
A check list serves as a check and double check against costly
omissions, mix-ups and errors. It is used to avoid mistakes and
ensure completeness of activities
There must be written procedures for process control activities i.e.
SOP. These procedures including changes, must be reviewed
and approved by the organizational unit and QA



                                                                       20
Documentation Practices


Permanent ink – No pencil

All pages numbered and filled out consecutively. No blanks to b

e filled in later

Blank or unused pages voided with a line, initiated and dated

Small “fill in the blank” lined out with”   “ or “N/A”.




                                                                  21
Control of Records


GMP DOCUMENTS shall not leave the company
 •   Do not take them home

Do not throw away GMP documents
Full reconciliation of each piece of document e.g. sample labels,
chromatograms, investigation report
Archive area
 •   Security Access
 •   Document Withdrawal and Return Log
 •   Smoke Alarms
 •   Off-site back system for electronic files
 •   Disaster recovery plan




                                                                    22
Electronic /Computerized Records


Records that are required to be maintained under predicate rule requirements
 •   Maintaining in electronic format in place of paper format – Part 11 records
 •   Maintain in electronic format in addition to paper format –rely on electronic record to
     perform regulated activities ( Business practices) –Part 11 records
 •   Document the business practices in an SOP
Audit trial for part 11 Records
Backup records are maintained for electronic records
Electronic data must be readily retrievable in a print format
Electronic signatures (e.g. approve, review and verify ) should be authenticated and
secure. When used such a system must be evaluated and tested for security,
validity and reliability, Records of those evaluations and tests must be maintained.
 During the retention period such records must be secured and accessible within 48
hours to manufacturer , packager, distributor and importer.




                                                                                               23
GMP Numbering System


Some documents require two numbers to be identified
completely,
• A document number – tells what it is
• A revision number –tells which one it is




                                                      24
SOP Numbers

Group SOPs by categories
•   Personnel
•   Quality Assurance
•   Quality Control
•   Records
•   Manufacturing
•   Packaging
•   Distribution
•   Building and facility
•   Equipment
•   Raw materials and packaging components
•   Development
•   Engineering
Recommend alphanumeric numbers and revision numbers e.g. QAD
123 v 03

                                                               25
Lot Numbers

Lot numbers are assigned as
 • Receiving Lot numbers
 • Production / in-house lot numbers
To trace an item or a product from planning , staging, production,
testing to market
To identify an item completely, both the lot number and the part
number are required




                                                                     26
Part Numbering System


Part number should be unique to each      A Simple Sample Part Numbering System
item
 •   Sodium Chloride USP Grade – Use in   1000-1999           Raw Materials*
     production
                                          2000-2999           Packaging Components*
 •   Sodium Chloride ACS Grade – Use in
                                          3000-3999           In-process Materials*
     laboratories
                                          4000-4999           Printed Materials and
Consider grouping by Suppliers                                Labels*
ERP,SAP, or Manual Inventory System       5000-5999           Finished Products*
 •   Numeric Numbering                    6000-6999           Materials Prepared
 •   Alpha-numeric numbering                                  In-house*
Part number can be retired but never      7000-7999           Non-inventory chemicals*
reassign Part numbers                     8000-8999           Non-inventory
                                                              Components*
                                          * Inventory Items




                                                                                     27
Document Numbers

Laboratory notebook number
Equipment logbook number
Validation Protocol Number
OOS number
CAPA number
Complaint number
Change number
…… etc



                             28
Types of Documents in Manufacturing


    Labels
    Specifications and testing procedures
    Master formulae and instructions
    Batch processing and batch packaging records
    Standard Operating Procedures (SOPs)
    Logbooks
    Records
       Stock control and distribution records
    Other documents …



                                                   29
Standard Operating Procedures

Written commitments to regulators that describe the routine tasks

Descriptions on how to perform various routine operations

Step by step instructions that technicians in QC, Production,
maintenance, and material handling consult daily in order to
complete their tasks reliably and consistently

Effective periods and review frequency




                                                                    30
SOP Format

Informational Categories
 •   Title
 •   Purpose
 •   Scope
 •   Responsibility
 •   Definitions
 •   Reference/ Applicable Documents
 •   Safety Considers
 •   Procedural principles
 •   Preliminary Operations
 •   Procedures
 •   Calculations
 •   Documentation Requirements
Each Page – Title, SOP number, revision number ,paginations, company name,
declaration of confidentiality
First page –approval signatures, date of approval , issue date, next review date


                                                                                   31
How to write good SOPs

SOP Numbering – simplify and group similar SOPs together
Reduce duplicate SOPs- facilitate training and improve compliance
Outside the job – Use process flow diagrams
Write for the readers – i.e. operators, analysts, QA, Customers,
Regulators
 •   Right language
 •   Short, simple sentences
 •   Familiar and short words
 •   Write in conversational style
 •   Explain the background, Do not assume people know / remember your processes
Use pictures to facilitate understanding, e.g. picture of an HPLC
Put procedures in a good package
 •   Selling SOPs to employees so that they will follow procedures
 •   Page design, instructions, table of contents , index , dividers, visual layout, right font
     size, and types of binders used, intranet access etc.




                                                                                                  32
Specifications and Test Procedures


Primary source of information for an item         Purchasing Information
Specification
 •   Specification number and version control      •   List of approved vendors
 •   Description of each part numbered item        •   Local Supplier – name and address
     - Standard Naming convention
 •   Name of company                               •   Manufacturer – Name and Address
 •   Expiration date/ Re-test date
 •   Chemical formula                              •   Minimum Order Quantity
 •   Material
 •   Dimensions                                    •   Quantity per Unit
 •   Sampling information e.g. size                •   Palletization Information
 •   Handling precautions
 •   Storage conditions                            •   Certificate of analysis
 •   Test requirements and method numbers
 •   Acceptance Criteria                           •   Contracts and Agreements
     - Test before release
     - Release based on C of A and
        concurrent testing
     - Release based on C of A and / or ID test
Pagination and approval signatures


                                                                                           33
Receiving Labels

Each item is labeled with its part number and receiving lot number
 •   Quantity per unit
 •   Total Quantity
 •   Total Number of pallets/ skids
 •   Responsible person – Initial and Date
 •   Transportation conditions
Different colors for different types of labels
 •   Quarantine Label – Yellow Color
 •   Sampled Label – Blue Color
 •   Under Hold Label – Orange Color
 •   Release Label - Green Color
 •   Rejection Label – Red Color
Barcode Labels
Label issuance, usage, destruction and reconciliation document


                                                                     34
Process Development Report

  The following exemplifies information to be contained in the development report.
•Historical data of pharmaceutical development of new drug substances and
          drug products at stages from early development phase to final application of
          approval
•Raw materials and components
•Synthetic route
•Rational for dosage form & formula designs and design of manufacturing methods
•Rational and change histories of important processes and control parameters
•Quality Profiles of manufacturing batches ( including stability data)
•Specifications and test methods of drug substances, intermediates, drug products, raw ma
terials, and components, and their rationale( validity of specification range
           of important tests such as contents impurities and dissolution, rational for selectio
n of test methods, reagents and, columns, and traceability of raw data of those
           information)
                                                                                                   35
Master Production Records


Prepare , sign and date by one     Production instructions
                                        Sequences to be followed
person and independently            •
                                    •   Critical steps have to be co-signed
check, sign and date by a               by a second operator/ supervisor
person in the Quality unit          •   Define the ranges of process
Product Description and item            parameters
                                    •   Sampling instructions and in-
number                                  process controls with acceptance
Full list of ingredients                criteria
Accurate statement of quantity      •   Time limits for completion of
                                        individual processing steps or total
or ratio of each raw material or        process
intermediate to be used             •   Expected yield ranges at
Production location, equipment          appropriate steps
                                        Special storage conditions including
and major utilities                 •
                                        labeling and packing materials
 Expected production quantity,      •   S             special precautions
sample quantity, rejects,
reprocessed quantity,% yield

                                                                               36
Production Batch Records

Check batch record before issuance to assure the correct version is used- sign
and date when issue
One batch record for one number ( unique number)
For continuous production, the product code with the date and time can serve as
the unique identifier until the final number is assigned
Full traceability of records- dates, times , personnel, equipment, raw materials,
actives, intermediates, packing components, labels, rejects, in-process and lab
results, OOS, investigations, changes, release changes, stability results,
environmental conditions etc…
Investigation of critical deviations – extend to other batches that may have been
associated with the specific failure or deviation
Document all deviations during manufacturing and cross reference to other
documents if necessary e.g. OOS or unplanned deviations
Attach all process generated paper to product batch records e.g. raw material
weighing records, tablet weight check, statistical process control charts,
equipment print outs, equipment and room labels etc.
Record production quantity, sample quantity, rejects, reprocessed quantity and %
yield
                                                                                    37
Production Record Review

Review and approve by the quality unit to determine compliance wit
h all established , approved written procedures before a batch is rele
ased or distributed
Any unexplained discrepancy or the failure of a batch or of its
components shall be thoroughly investigated, whether or not the bat
ch has already been distributed
The investigation shall extend to other batches
A written record of the investigation shall be made and shall include
the conclusions and follow-up




                                                                     38
Packaging Instructions

Master packaging instruction – formally authorized
Packaging instruction
• Strengths, dosage forms, size( by volume, weight or counts), packaging
  materials, packaged lot number
• Location of packaging line
• Date, time and personnel
• Labels and print components – keep samples coded with lot number and
  expiry date, reconciliation and control
• Line clearance checks – before and after
• In-process controls from shift to shift
• Samples control
• Special precautions




                                                                           39
Equipment Records


Usage logs

 •   Product / Batch Number/ Person/ Date/ Time

Cleaning/ Sanitation/ Sterilization

Maintenance

 •   Person, date, time, results

Dedicate Equipment – One intermediate or one product

 •   Individual equipment records are not necessary if batches are traceable

     sequence

                                                                               40
Laboratory Glassware

All in-process solutions, glassware, media tubes or plates, samp
le extracts and anything used in testing must be clearly labeled
and identified
Laboratory glassware with labels are kept until laboratory
reports are reviewed and approved



                             Product                  : ABC
                             Lot Number               : 130
                             Sample                   :#1
                             Analyst initial & Date   :




                                                                   41
Raw material and Packaging
        Component Records

External
•   Name(s) of manufacturer/distributor
•   Batch Number/ Item Number/ Labeling
•   Quantity of each shipment / Quantity per skid / Quantity per unit
•   Date of receipt/ expiry date
•   Certificate of analysis

Internal
•   Receiving Number / Item number/ Labeling
•   Sample Size
•   Test Specification, Identification/ Test Results and release decision
•   Packaging components, printed components and labels
•   Master approved labels and components for comparison
•   Inventory of each item, usage records for each material and rejection


                                                                            42
Laboratory Records

Complete lab data derived from all tests and lab equipment
Compliance with established specifications and standards
Full traceability – dates, time, samples, quantities , suppliers, personnel,
equipment, reference standards, reagents, standard solutions, test
methods, graphs, charts, spectra, chromatograms, calculations,
conversion factors, test results, comparison to previous trends and
validation batches, changes to methods, OOS
 Signature of the person who performed each test and the dates(s) the
tests performed
Signature and date of second person showing that the original records
have been reviewed for accuracy, completeness and compliance with
established standards.




                                                                               43
Laboratory Data


Raw data are necessary for support, reconstruction and
evaluation of test report

Raw data may include , but is not limited to , photographs,
microfilm, computer printouts, labels, magnetic media, including
dictated observations, and recorded data from automated
instruments

All raw data are kept with the test reports, unless there are
electronic records or other means of recording


                                                                   44
Out of Specification and Re-testing



OOS FORM Plus all related documents

Initiate OOS investigation as soon as OOS is found

Any repeat testing or retesting due to laboratory error or instrument

problems must be approved by management prior to testing again

Only management has the authority to invalidate a result




                                                                        45
Data Review


The raw data and lab records are very important
Documents
Before any product is released to the market, a
complete check of production and laboratory
records is made to make sure the product meets
the quality standards
When you sign your name on the appropriate
records, you are, in essence becoming an
historian for that process.


                                                  46
Stability Records


Demonstrate that the product meets its established s
pecifications during the product shelf life
Test product in its final package in which it is sold
On-going stability program: 0,3,6,9,12,18,24,36 …mo
nths
Test with in the required time frame




                                                        47
Deviation Records


Deviation Form + all related documents
Full investigation – Describe the background , the environment,
personnel involved, root causes , risk assessment , conclusions,
corrective and preventive actions(CAPA)
Write with short and simple sentences
Write for someone who does not know your procedures
Write for someone who will read this document few years from
now.



                                                                   48
Change Control Records

Regulations and Requirements                   -What functions a Change Control system must
- Change control as critical part of the         perform
   validation life cycle                       - How the organizational culture can affect the
- How to set up Change Control,                  successful implementation of Change Control
   Documentation Systems                       - Types of Changes
- Preparing Change Control SOPS & Forms        - Different levels of change (major, minor, critical)
- Processes involved to efficiently control      and distinguishing them
   and document changes to:                    - Types of reviews and approvals
- Manufacturing processes                      - Roles and Responsibilities
- Facilities                                     Signature meanings
- Product                                      - How your Change Control system may be
- Elements of Change Control Management          examined by investigators
- Change Control process for computerized      - Change Control checklists
                                               - Personnel Training
  systems                                      - Scale Up and Post Approval Changes – SUPAC
- Change Control in API and Drug Product       - Bulk Actives Post Approval Changes - BACPAC
  industries
- How to organize change documentation to
   withstand regulatory queries during field
    inspections?

                                                                                                       49
Training Records

It is the responsibility of each employee/management to maintain their own
and their department's training records
You can perform a test or task until you and your trainer have completed the trai
ning and signed -off on the procedure.
Certain tests require performance assessment before Qualification
Must document the training on new and revised SOPs issued throughout the ye
ar.
Training Records should be reviewed during annual performance review
between the manager and the employee. Document any additional training
for the new year.
For human errors on OOS or deviations – employee training records need to cro
ss link to corrective and preventive actions.




                                                                                    50
Organisation Charts


 Dated and version control
Name of all personnel involved in GMP activities and
decision making.
Provide information on full time, part time and contract
staff.
Provide global reporting structures for multinational
organizations.




                                                           51
Job Description


Job descriptions are written statements that describe the:
• Duties,
• Responsibilities,
most important contributions and outcomes needed from a position, required qualifications
of candidates, and reporting relationship and co-workers of a
particular job.
Job descriptions are based on objective information obtained through job analysis, an
understanding of the competencies and skills required to accomplish needed tasks, and
 the needs of the organization to produce work.
Job descriptions clearly identify and spell out the responsibilities of a specific job.
Job descriptions also include information about working conditions, tools, equipment
used, knowledge and skills needed, and relationships with other positions.
The best job descriptions are living, breathing documents that are updated as
responsibilities change.
The best job descriptions do not limit employees, but rather, cause them to stretch their
experience, grow their skills, and develop their ability to contribute within their
organization.

                                                                                            52
Technology Transfer Documents

 Like for like transfers.
Levels of changes require for changes.
Risk assessment for changes within the “Design Space”
From one site to another site.
From R&D to production
Transfer protocols – before and after
Change control or deviation during transfer
Validation status after transfers
Stability studies

                                                        53
Validation Documentation


Validation Protocol – before validation
 •   How validation of a particular process will be conducted
 •   Specify the type of validation e.g. retrospective, prospective or concurrent and the number of
     process runs
 •   Specify critical process steps and acceptance criteria
     - Important to put down the pre-determined specifications otherwise , any result can be
        claimed as ‘ validated’.
     - Important to justify which are the priority parameters to be validated , since we may not be
        able to validate all combinations of results

Validation Report – After Validation
 •   Cross reference the validation protocol
 •   Summarize the results, deviations, changes and conclusions
 •   Recommend changes to correct deficiencies
 •   Justify any variations from the protocol
 •   Review and approve by the designated units and QA

                                                                                                      54
Management Review Minutes


Attendance
Meeting Dates and Frequency
Discussions of Quality trends and issues
• Identify responsible person(s) for CAPA
• Target dates for actions

Follow-up with previous minutes and actions
Escalation Process


                                              55
Documents involved External Stake Holders


Response to Regulatory Inspections
Responses to customer inspections
Complaints
Product Recalls
Annual Product Quality Review
Post- market adverse drug events reports
Write for the readers
Write for the future


                                            56
Response to Regulatory Inspections

Respond on time
A cover letter and a separate on responses
Understand the GMP aspects of comments and respond to
the comments
Identify root causes
Provide corrective and preventive actions with target dates
Include responsible department/function –names are not
necessary




                                                              57
Complaints

SOPs for handling of all written and oral complaints
Train all employees on how to document complaints
Complaints involving the possible failure of drug product to meet
any of its specifications – to be reviewed by the Quality Control Unit
Complaint represent serious and unexpected adverse drug
experience – require to be reported to FDA
Maintain complaint records at least 1 year after the expiration date
of the product or 1 year after the date that the complaint was
received, whichever is longer
Where investigation is not conducted, the written record shall
include the justification that an investigation was not necessary and the
name of the responsible person making such a determination


                                                                            58
Product Recalls

Investigations, root cause analysis, CAPA
Different levels of recalls have different regulatory
requirements
 • Class- 1 – Recall from the market place
 • Class-2
 • Class-3

Distribution records – Full Traceability of Quantities
distributed and the customers
 •   Includes sales records of drugs and professional samples
 •   Enable a complete rapid recall of any lot or batch of a drug



                                                                    59
Health and Hygiene Records

Sanitation and hygiene should be practiced to
avoid contamination of personnel and during
manufacturing of products.
It should cover all aspects of manufacturing:
   Personnel
   Premises
   Equipment and apparatus
   Production materials and containers
   Products for cleaning and sanitation
   All potential sources of contamination




                                                60
Pest and Rodent Control Records

Written pest control program
Pest Control and Rodent Control Site map
Log book of Rodent and Insect Traps
Insect and Rodent Trap cleaning record
Outsourcing is recommended
Use of safe pest control agents
MSDS of all pest control agents
No risk of contamination to the materials and
products
Proper records




                                                61
Regulatory Observation Related to Documentation
                     Issues

   There are no written procedures for production and process controls designed to assure that t
   he drug products have the identity, strength, quality and purity they purport to possess.
   Written procedures have not been developed for the surveillance, and receipt of post
   marketing adverse drug events.
   Firm failed to follow their SOPs on OOS investigations. Samples were re-tested before any investigat
   ion was conducted.
   The operator who manufactured a batch of sterile product has no documented training on
    sterile production.
   Investigations fail to be conducted within a timely manner. The time frame for completion is required i
   n SOP. The SOP places no limitations for the number of times a time frame may be
   extended, nor does it identify the number of days allowed to extend a timeframe.
   A portion of batch was rejected. The in-process solution made for the rejected portion of the
   batch was not reconciled .There was no record of the disposition of the excess quantity of the
   excess material.
   Lab records are deficient in that they do not include a complete record of all data generated
   during testing. There was no record on how many chromatograms were generated.
   The firm communicated GMP related information through electronic mails .Investigation and
   product decisions were made on emails. Contents of these emails are not archived or
   transcribed in to formalized records required by the regulations.

                                                                                                             62
Stock Control and Distribution Records

    What should be recorded?
    Where should records be stored?
    Why are the records important?




                                         63
Design a Good Documentation System


Not a one size fits all approach

Unique operations and unique products

Complement the cultural environment of the corporation

Be the expert in your systems, operations, products and

services.

Do not create a system to satisfy one part of the corporation


                                                 J.Ramniwas     64
Revision and Renewal of Documents

   Should be made periodically, or if needed
   Obsolete documents should be retrieved from
   all relevant parties and its original copy should
   be archived
   The date of revision should be stated in the
   new documents
   Every revision should be approved by
   authorized person



                                              J.Ramniwas   65
A Good Documentation Practice:
    A Life Style Approach

When you care enough to make GDP a life style and not just a r
egulation, you do more the signing documents – we put our nam
e on job well done.
Write it down – Keep good records
If it is not documented, it is a rumour
There can be no substitute for a clear commitment to entering d
ata
•   Correctly
•   Completely and
•   Chronologically
    and right first time




                                                      J.Ramniwas   66

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Importance of documentation for gmp compliance

  • 1. Importance of Documentation in GMP compliance By: J.Ramniwas Director-Regulatory and Quality Affairs Pharmaocean,Vadodara(India) 1
  • 2. Objective • To review general requirements for documents • To review specific requirements for each document • To give general guidance how to create good documentation system •A reliable evidence for GMP compliance. •Quality by design is the only solution to overcome the quality-related complaints in an organisation. •An essential element of quality assurance is good documentation practices. •The system of documentation devised or adopted should have as its main objective to establish, monitor, and record “quality” for all aspects of the production, quality control and quality assurance 2
  • 3. Purpose of Documentation Clearly written documentation prevents errors that may arise in or al or casually written communication It provides assurance that quality related activities are carried out exactly the way they have been planned and approved The achievement of conformity and quality improvement Purpose of documentation : To ensure that there are specifications for all materials and m ethods of manufacture and control Employees know what to do Responsibilities and authorities are identified Ensure that authorized persons have all information necessary for release Provide audit trail Forms the basis for improvement. 3
  • 4. Quality Based Documentation System Corporate Communication tool – internal and external Integral part of corporate interactions Corporate Policies – Rationale for responsible decision making Currency of corporation 4
  • 5. Quality Policy and its Importance Management commitment to quality •Customer Focused Satisfy our customers' needs and expectations •Make commitments we fully understand and believe we can meet •Meet all commitments to customers on time Performance Driven 1. Verify that our products and services meet agreed requirements 2.Monitor, benchmark and continuously improve our business, products and services, organization and employees' performance Achieve Organisation's Mission and Goals 1. Sustain and develop business growth and Intellectual Property 5
  • 6. Quality Manual The strategic document that outlines the organization’s system of providing quality assurance to achieve customer satisfaction Objectives : Describe the quality system structure Declare the quality policy and organization goal Describe how the organization meets the quality goal Content of quality manual : The quality policy declaration The goal of quality; The organisational structure including responsibility and aut hority of each key personnel Procedures, instructions and resources for implementing the quality management. User : All personnel in the organization Another parties, auditors, and customers 6
  • 8. Type of GMP Documents 1. Description Documents • Describe how to perform certain tasks • E.g.. SOPs, Protocols, Specifications, Master Production Records etc. 2. Data Collection Documents • Facilitate the timely and accurate documentation of tasks and events • E.g. Forms, Reports, Production Batch Records , Logbooks etc. 3. Numbering Systems • Serves to account for and track information and documents • E.g. Lot numbers, Part numbers, equipment numbers, Form numbers, SOP numbers, Receiving codes etc. 4. Data Files • Serves to organize the data in to useful categories for review and to support accountability and traceability requirements • E.g. Specification Files, Equipment Files, Equipment history files, Product files, Facility Qualification files etc. J.Ramniwas 8
  • 9. Function of GMP Documents • Establish, monitor and document Quality 1. Description Documents Define and establish the Quality of Raw materials, environment, production process and Finished Product 2. Data Collection Documents Confirm the materials ,environment , production processes or product routinely meet the established Quality characteristics. 3. Numbering Systems Control and track the use of descriptive documents and data collection documents 4. Data Files Organize the data in to useful categories to facilitate review and retrieval 9
  • 10. Users 1. Bottom –up • Manufacturing, Laboratory or Operational personnel who interact with the detailed steps of the system on a daily basis • Need to know what to do and how to do it 2. Top-Down • Administrative personnel e.g. management, regulatory, development, finance, marketing who must understand and interact with the system by reference • A good document is written both to inform and to educate • It must meet the needs of the line workers and the administrators E.g. SOP on specification writing- describes the purpose of specifications, provide guidance on the decision making associated with writing specifications, numbering systems, change controls and responsible personnel, steps on generating and approving an SOP etc. 10
  • 11. A Well Designed Documentation System Ensure Quality standards are met routinely Minimize the potential for Error Reduce downtime when deviations or failures occur by providing immediate access to well organized data Serve as a consistent training tool for line workers and administrators GMP documents should be prepared, reviewed, approved, distributed and archived according to written procedures. A Poorly Designed System is a burden to all! A simple system is always the most difficult to design. J.Ramniwas 11
  • 12. Manufacturer's Role Comply with GMP regulations Provide Quality medications to patients Provide documentation to support the quality of the products from development to market and to product discontinuation Producing documents is also part of the production 12
  • 13. Principles of Good Documentation The heart of GMP is the establishment of well written procedures for each step of our quality operations Documentation is used for full traceability of events – cross reference all related documents – audit Written procedures provide the controls necessary to minimize the changes, mix-ups and errors Ensure compliance with GMP regulations but more importantly, we ensure the consistent Quality of our products. 13
  • 14. Proof of Quality • As a pharmaceutical company, your proof of success is found in the documents records that you keep. • Documentation is your proof that your products/ services are produced in compliance with the GMP regulations and your company’s operating procedures and standards. • Key Documents : Development Records, Clinical Trial Records, process and method validation, production batch records, OOS, Deviations, Investigations, Equipment Calibration and preventive maintenance, Training Records, CAPA, Complaints, Change Control etc.. 14
  • 15. Who Reads your Documents Internal • Colleagues • Supervisors and managers • Data Reviewers • QA • Global Network Colleagues External • Regulators – Local and Foreign • Customers – Local and Foreign • Lawyers • General Public Write documents as though you are writing history. Write for future viewers 15
  • 16. Basics of Record Keeping • Where your signature is required, write your name legibly and in ink – always use include the date of signing. • Always document as soon as a task is performed • For all critical steps, a second person is required to verify the entered data • Do not document someone else’s work unless you are designated to do so. • Do not assume work has been properly documented without seeing the work and / or the documents, e.g. blame for fraudulent action 16
  • 17. Real Time Formats and Dates • Data entered directly as it occurs • Scratch paper or sticky notes must not be used • Records are signed and dated on the day (and time) the work was performed • Consistent date format is important for a company e.g. day/month/year or year/month/day • Alpha-numeric dating is preferred • 01 Nov 2008 is preferred over 01-11-2008 • Each page should have the current date(s) – no back dating. 17
  • 18. Calculation and Numbers Write down the formula and perform one sample calculation. No calculation is required for simple math e.g. 1+4 =5 Prevent using down arrow or ditto marks to show repetitiveness e.g. 18
  • 19. Corrections No over written No use of white fluid No out Critical corrections or omissions must be addressed and signed by management on raw data record Data on damaged pages should be re-entered for clarity, initial, date and explanation All corrections must be initiated and dated by the analyst and reviewer when applikable applicable John 01 Nov.2008 19
  • 20. Documentation Practices Documentation requires that record, sign and date every step of the operations that we perform e.g. production batch records Documentation should always be done promptly, accurately, legibly and in accord with our written procedures e.g. lab notebooks A check list serves as a check and double check against costly omissions, mix-ups and errors. It is used to avoid mistakes and ensure completeness of activities There must be written procedures for process control activities i.e. SOP. These procedures including changes, must be reviewed and approved by the organizational unit and QA 20
  • 21. Documentation Practices Permanent ink – No pencil All pages numbered and filled out consecutively. No blanks to b e filled in later Blank or unused pages voided with a line, initiated and dated Small “fill in the blank” lined out with” “ or “N/A”. 21
  • 22. Control of Records GMP DOCUMENTS shall not leave the company • Do not take them home Do not throw away GMP documents Full reconciliation of each piece of document e.g. sample labels, chromatograms, investigation report Archive area • Security Access • Document Withdrawal and Return Log • Smoke Alarms • Off-site back system for electronic files • Disaster recovery plan 22
  • 23. Electronic /Computerized Records Records that are required to be maintained under predicate rule requirements • Maintaining in electronic format in place of paper format – Part 11 records • Maintain in electronic format in addition to paper format –rely on electronic record to perform regulated activities ( Business practices) –Part 11 records • Document the business practices in an SOP Audit trial for part 11 Records Backup records are maintained for electronic records Electronic data must be readily retrievable in a print format Electronic signatures (e.g. approve, review and verify ) should be authenticated and secure. When used such a system must be evaluated and tested for security, validity and reliability, Records of those evaluations and tests must be maintained. During the retention period such records must be secured and accessible within 48 hours to manufacturer , packager, distributor and importer. 23
  • 24. GMP Numbering System Some documents require two numbers to be identified completely, • A document number – tells what it is • A revision number –tells which one it is 24
  • 25. SOP Numbers Group SOPs by categories • Personnel • Quality Assurance • Quality Control • Records • Manufacturing • Packaging • Distribution • Building and facility • Equipment • Raw materials and packaging components • Development • Engineering Recommend alphanumeric numbers and revision numbers e.g. QAD 123 v 03 25
  • 26. Lot Numbers Lot numbers are assigned as • Receiving Lot numbers • Production / in-house lot numbers To trace an item or a product from planning , staging, production, testing to market To identify an item completely, both the lot number and the part number are required 26
  • 27. Part Numbering System Part number should be unique to each A Simple Sample Part Numbering System item • Sodium Chloride USP Grade – Use in 1000-1999 Raw Materials* production 2000-2999 Packaging Components* • Sodium Chloride ACS Grade – Use in 3000-3999 In-process Materials* laboratories 4000-4999 Printed Materials and Consider grouping by Suppliers Labels* ERP,SAP, or Manual Inventory System 5000-5999 Finished Products* • Numeric Numbering 6000-6999 Materials Prepared • Alpha-numeric numbering In-house* Part number can be retired but never 7000-7999 Non-inventory chemicals* reassign Part numbers 8000-8999 Non-inventory Components* * Inventory Items 27
  • 28. Document Numbers Laboratory notebook number Equipment logbook number Validation Protocol Number OOS number CAPA number Complaint number Change number …… etc 28
  • 29. Types of Documents in Manufacturing Labels Specifications and testing procedures Master formulae and instructions Batch processing and batch packaging records Standard Operating Procedures (SOPs) Logbooks Records Stock control and distribution records Other documents … 29
  • 30. Standard Operating Procedures Written commitments to regulators that describe the routine tasks Descriptions on how to perform various routine operations Step by step instructions that technicians in QC, Production, maintenance, and material handling consult daily in order to complete their tasks reliably and consistently Effective periods and review frequency 30
  • 31. SOP Format Informational Categories • Title • Purpose • Scope • Responsibility • Definitions • Reference/ Applicable Documents • Safety Considers • Procedural principles • Preliminary Operations • Procedures • Calculations • Documentation Requirements Each Page – Title, SOP number, revision number ,paginations, company name, declaration of confidentiality First page –approval signatures, date of approval , issue date, next review date 31
  • 32. How to write good SOPs SOP Numbering – simplify and group similar SOPs together Reduce duplicate SOPs- facilitate training and improve compliance Outside the job – Use process flow diagrams Write for the readers – i.e. operators, analysts, QA, Customers, Regulators • Right language • Short, simple sentences • Familiar and short words • Write in conversational style • Explain the background, Do not assume people know / remember your processes Use pictures to facilitate understanding, e.g. picture of an HPLC Put procedures in a good package • Selling SOPs to employees so that they will follow procedures • Page design, instructions, table of contents , index , dividers, visual layout, right font size, and types of binders used, intranet access etc. 32
  • 33. Specifications and Test Procedures Primary source of information for an item Purchasing Information Specification • Specification number and version control • List of approved vendors • Description of each part numbered item • Local Supplier – name and address - Standard Naming convention • Name of company • Manufacturer – Name and Address • Expiration date/ Re-test date • Chemical formula • Minimum Order Quantity • Material • Dimensions • Quantity per Unit • Sampling information e.g. size • Palletization Information • Handling precautions • Storage conditions • Certificate of analysis • Test requirements and method numbers • Acceptance Criteria • Contracts and Agreements - Test before release - Release based on C of A and concurrent testing - Release based on C of A and / or ID test Pagination and approval signatures 33
  • 34. Receiving Labels Each item is labeled with its part number and receiving lot number • Quantity per unit • Total Quantity • Total Number of pallets/ skids • Responsible person – Initial and Date • Transportation conditions Different colors for different types of labels • Quarantine Label – Yellow Color • Sampled Label – Blue Color • Under Hold Label – Orange Color • Release Label - Green Color • Rejection Label – Red Color Barcode Labels Label issuance, usage, destruction and reconciliation document 34
  • 35. Process Development Report The following exemplifies information to be contained in the development report. •Historical data of pharmaceutical development of new drug substances and drug products at stages from early development phase to final application of approval •Raw materials and components •Synthetic route •Rational for dosage form & formula designs and design of manufacturing methods •Rational and change histories of important processes and control parameters •Quality Profiles of manufacturing batches ( including stability data) •Specifications and test methods of drug substances, intermediates, drug products, raw ma terials, and components, and their rationale( validity of specification range of important tests such as contents impurities and dissolution, rational for selectio n of test methods, reagents and, columns, and traceability of raw data of those information) 35
  • 36. Master Production Records Prepare , sign and date by one Production instructions Sequences to be followed person and independently • • Critical steps have to be co-signed check, sign and date by a by a second operator/ supervisor person in the Quality unit • Define the ranges of process Product Description and item parameters • Sampling instructions and in- number process controls with acceptance Full list of ingredients criteria Accurate statement of quantity • Time limits for completion of individual processing steps or total or ratio of each raw material or process intermediate to be used • Expected yield ranges at Production location, equipment appropriate steps Special storage conditions including and major utilities • labeling and packing materials Expected production quantity, • S special precautions sample quantity, rejects, reprocessed quantity,% yield 36
  • 37. Production Batch Records Check batch record before issuance to assure the correct version is used- sign and date when issue One batch record for one number ( unique number) For continuous production, the product code with the date and time can serve as the unique identifier until the final number is assigned Full traceability of records- dates, times , personnel, equipment, raw materials, actives, intermediates, packing components, labels, rejects, in-process and lab results, OOS, investigations, changes, release changes, stability results, environmental conditions etc… Investigation of critical deviations – extend to other batches that may have been associated with the specific failure or deviation Document all deviations during manufacturing and cross reference to other documents if necessary e.g. OOS or unplanned deviations Attach all process generated paper to product batch records e.g. raw material weighing records, tablet weight check, statistical process control charts, equipment print outs, equipment and room labels etc. Record production quantity, sample quantity, rejects, reprocessed quantity and % yield 37
  • 38. Production Record Review Review and approve by the quality unit to determine compliance wit h all established , approved written procedures before a batch is rele ased or distributed Any unexplained discrepancy or the failure of a batch or of its components shall be thoroughly investigated, whether or not the bat ch has already been distributed The investigation shall extend to other batches A written record of the investigation shall be made and shall include the conclusions and follow-up 38
  • 39. Packaging Instructions Master packaging instruction – formally authorized Packaging instruction • Strengths, dosage forms, size( by volume, weight or counts), packaging materials, packaged lot number • Location of packaging line • Date, time and personnel • Labels and print components – keep samples coded with lot number and expiry date, reconciliation and control • Line clearance checks – before and after • In-process controls from shift to shift • Samples control • Special precautions 39
  • 40. Equipment Records Usage logs • Product / Batch Number/ Person/ Date/ Time Cleaning/ Sanitation/ Sterilization Maintenance • Person, date, time, results Dedicate Equipment – One intermediate or one product • Individual equipment records are not necessary if batches are traceable sequence 40
  • 41. Laboratory Glassware All in-process solutions, glassware, media tubes or plates, samp le extracts and anything used in testing must be clearly labeled and identified Laboratory glassware with labels are kept until laboratory reports are reviewed and approved Product : ABC Lot Number : 130 Sample :#1 Analyst initial & Date : 41
  • 42. Raw material and Packaging Component Records External • Name(s) of manufacturer/distributor • Batch Number/ Item Number/ Labeling • Quantity of each shipment / Quantity per skid / Quantity per unit • Date of receipt/ expiry date • Certificate of analysis Internal • Receiving Number / Item number/ Labeling • Sample Size • Test Specification, Identification/ Test Results and release decision • Packaging components, printed components and labels • Master approved labels and components for comparison • Inventory of each item, usage records for each material and rejection 42
  • 43. Laboratory Records Complete lab data derived from all tests and lab equipment Compliance with established specifications and standards Full traceability – dates, time, samples, quantities , suppliers, personnel, equipment, reference standards, reagents, standard solutions, test methods, graphs, charts, spectra, chromatograms, calculations, conversion factors, test results, comparison to previous trends and validation batches, changes to methods, OOS Signature of the person who performed each test and the dates(s) the tests performed Signature and date of second person showing that the original records have been reviewed for accuracy, completeness and compliance with established standards. 43
  • 44. Laboratory Data Raw data are necessary for support, reconstruction and evaluation of test report Raw data may include , but is not limited to , photographs, microfilm, computer printouts, labels, magnetic media, including dictated observations, and recorded data from automated instruments All raw data are kept with the test reports, unless there are electronic records or other means of recording 44
  • 45. Out of Specification and Re-testing OOS FORM Plus all related documents Initiate OOS investigation as soon as OOS is found Any repeat testing or retesting due to laboratory error or instrument problems must be approved by management prior to testing again Only management has the authority to invalidate a result 45
  • 46. Data Review The raw data and lab records are very important Documents Before any product is released to the market, a complete check of production and laboratory records is made to make sure the product meets the quality standards When you sign your name on the appropriate records, you are, in essence becoming an historian for that process. 46
  • 47. Stability Records Demonstrate that the product meets its established s pecifications during the product shelf life Test product in its final package in which it is sold On-going stability program: 0,3,6,9,12,18,24,36 …mo nths Test with in the required time frame 47
  • 48. Deviation Records Deviation Form + all related documents Full investigation – Describe the background , the environment, personnel involved, root causes , risk assessment , conclusions, corrective and preventive actions(CAPA) Write with short and simple sentences Write for someone who does not know your procedures Write for someone who will read this document few years from now. 48
  • 49. Change Control Records Regulations and Requirements -What functions a Change Control system must - Change control as critical part of the perform validation life cycle - How the organizational culture can affect the - How to set up Change Control, successful implementation of Change Control Documentation Systems - Types of Changes - Preparing Change Control SOPS & Forms - Different levels of change (major, minor, critical) - Processes involved to efficiently control and distinguishing them and document changes to: - Types of reviews and approvals - Manufacturing processes - Roles and Responsibilities - Facilities Signature meanings - Product - How your Change Control system may be - Elements of Change Control Management examined by investigators - Change Control process for computerized - Change Control checklists - Personnel Training systems - Scale Up and Post Approval Changes – SUPAC - Change Control in API and Drug Product - Bulk Actives Post Approval Changes - BACPAC industries - How to organize change documentation to withstand regulatory queries during field inspections? 49
  • 50. Training Records It is the responsibility of each employee/management to maintain their own and their department's training records You can perform a test or task until you and your trainer have completed the trai ning and signed -off on the procedure. Certain tests require performance assessment before Qualification Must document the training on new and revised SOPs issued throughout the ye ar. Training Records should be reviewed during annual performance review between the manager and the employee. Document any additional training for the new year. For human errors on OOS or deviations – employee training records need to cro ss link to corrective and preventive actions. 50
  • 51. Organisation Charts Dated and version control Name of all personnel involved in GMP activities and decision making. Provide information on full time, part time and contract staff. Provide global reporting structures for multinational organizations. 51
  • 52. Job Description Job descriptions are written statements that describe the: • Duties, • Responsibilities, most important contributions and outcomes needed from a position, required qualifications of candidates, and reporting relationship and co-workers of a particular job. Job descriptions are based on objective information obtained through job analysis, an understanding of the competencies and skills required to accomplish needed tasks, and the needs of the organization to produce work. Job descriptions clearly identify and spell out the responsibilities of a specific job. Job descriptions also include information about working conditions, tools, equipment used, knowledge and skills needed, and relationships with other positions. The best job descriptions are living, breathing documents that are updated as responsibilities change. The best job descriptions do not limit employees, but rather, cause them to stretch their experience, grow their skills, and develop their ability to contribute within their organization. 52
  • 53. Technology Transfer Documents Like for like transfers. Levels of changes require for changes. Risk assessment for changes within the “Design Space” From one site to another site. From R&D to production Transfer protocols – before and after Change control or deviation during transfer Validation status after transfers Stability studies 53
  • 54. Validation Documentation Validation Protocol – before validation • How validation of a particular process will be conducted • Specify the type of validation e.g. retrospective, prospective or concurrent and the number of process runs • Specify critical process steps and acceptance criteria - Important to put down the pre-determined specifications otherwise , any result can be claimed as ‘ validated’. - Important to justify which are the priority parameters to be validated , since we may not be able to validate all combinations of results Validation Report – After Validation • Cross reference the validation protocol • Summarize the results, deviations, changes and conclusions • Recommend changes to correct deficiencies • Justify any variations from the protocol • Review and approve by the designated units and QA 54
  • 55. Management Review Minutes Attendance Meeting Dates and Frequency Discussions of Quality trends and issues • Identify responsible person(s) for CAPA • Target dates for actions Follow-up with previous minutes and actions Escalation Process 55
  • 56. Documents involved External Stake Holders Response to Regulatory Inspections Responses to customer inspections Complaints Product Recalls Annual Product Quality Review Post- market adverse drug events reports Write for the readers Write for the future 56
  • 57. Response to Regulatory Inspections Respond on time A cover letter and a separate on responses Understand the GMP aspects of comments and respond to the comments Identify root causes Provide corrective and preventive actions with target dates Include responsible department/function –names are not necessary 57
  • 58. Complaints SOPs for handling of all written and oral complaints Train all employees on how to document complaints Complaints involving the possible failure of drug product to meet any of its specifications – to be reviewed by the Quality Control Unit Complaint represent serious and unexpected adverse drug experience – require to be reported to FDA Maintain complaint records at least 1 year after the expiration date of the product or 1 year after the date that the complaint was received, whichever is longer Where investigation is not conducted, the written record shall include the justification that an investigation was not necessary and the name of the responsible person making such a determination 58
  • 59. Product Recalls Investigations, root cause analysis, CAPA Different levels of recalls have different regulatory requirements • Class- 1 – Recall from the market place • Class-2 • Class-3 Distribution records – Full Traceability of Quantities distributed and the customers • Includes sales records of drugs and professional samples • Enable a complete rapid recall of any lot or batch of a drug 59
  • 60. Health and Hygiene Records Sanitation and hygiene should be practiced to avoid contamination of personnel and during manufacturing of products. It should cover all aspects of manufacturing: Personnel Premises Equipment and apparatus Production materials and containers Products for cleaning and sanitation All potential sources of contamination 60
  • 61. Pest and Rodent Control Records Written pest control program Pest Control and Rodent Control Site map Log book of Rodent and Insect Traps Insect and Rodent Trap cleaning record Outsourcing is recommended Use of safe pest control agents MSDS of all pest control agents No risk of contamination to the materials and products Proper records 61
  • 62. Regulatory Observation Related to Documentation Issues There are no written procedures for production and process controls designed to assure that t he drug products have the identity, strength, quality and purity they purport to possess. Written procedures have not been developed for the surveillance, and receipt of post marketing adverse drug events. Firm failed to follow their SOPs on OOS investigations. Samples were re-tested before any investigat ion was conducted. The operator who manufactured a batch of sterile product has no documented training on sterile production. Investigations fail to be conducted within a timely manner. The time frame for completion is required i n SOP. The SOP places no limitations for the number of times a time frame may be extended, nor does it identify the number of days allowed to extend a timeframe. A portion of batch was rejected. The in-process solution made for the rejected portion of the batch was not reconciled .There was no record of the disposition of the excess quantity of the excess material. Lab records are deficient in that they do not include a complete record of all data generated during testing. There was no record on how many chromatograms were generated. The firm communicated GMP related information through electronic mails .Investigation and product decisions were made on emails. Contents of these emails are not archived or transcribed in to formalized records required by the regulations. 62
  • 63. Stock Control and Distribution Records What should be recorded? Where should records be stored? Why are the records important? 63
  • 64. Design a Good Documentation System Not a one size fits all approach Unique operations and unique products Complement the cultural environment of the corporation Be the expert in your systems, operations, products and services. Do not create a system to satisfy one part of the corporation J.Ramniwas 64
  • 65. Revision and Renewal of Documents Should be made periodically, or if needed Obsolete documents should be retrieved from all relevant parties and its original copy should be archived The date of revision should be stated in the new documents Every revision should be approved by authorized person J.Ramniwas 65
  • 66. A Good Documentation Practice: A Life Style Approach When you care enough to make GDP a life style and not just a r egulation, you do more the signing documents – we put our nam e on job well done. Write it down – Keep good records If it is not documented, it is a rumour There can be no substitute for a clear commitment to entering d ata • Correctly • Completely and • Chronologically and right first time J.Ramniwas 66