Pharmaceutical Facility Design
PhEn-602 J. Manfredi Section 102 (Wed.)
PhEn602-Pharmaceutical Facility Design-Spring 2009
PhEn602-Pharmaceutical Facility Design-Spring 2009
PhEn602-Pharmaceutical Facility Design-Spring 2009
Pharmaceutical Facility Design PhEn 602 Syllabus
Term: 2009 Spring Semester NJIT Course Title: Pharmaceutical Facility Design NJIT Course Number: PhEn 602, Section 102 (Wed.) Course Instructor: Joseph J. Manfredi Adjunct Professor New Jersey Institute of Technology Department of Chemical Engineering University Heights Newark, NJ 07102-1982 Instructors Telephone & Fax: Ph: (973) 575-4990 Fax: (973) 808-9201
Instructors E-Mail Address: [email protected] Instructors Office Hours: As an adjunct faculty member, Prof. Manfredi does not maintain an office on campus. Students may contact him, preferably by email, to schedule a meeting, to pose questions, or to request clarifications regarding course materials. Responses will be handled as quickly as possible, subject to scheduling, travel and other prior commitments. Phone calls should be limited to emergencies only. Prof. Manfredi will generally be available prior to and after each class for discussion. Grader/Assistant: None Course Day and Time: Wed. (Sect. 102) 6:00 9:05 p.m. Location: NJIT, Newark, NJ, Kupfrian Hall , Room 110
PhEn602-Pharmaceutical Facility Design-Spring 2009
Course Prerequisites: Graduate Standing PhEn-601 Principles of Pharmaceutical Engineering PhEn-603 Pharmaceutical Processing and Manufacturing Permission by the Instructor or the Program Director Course Description: This course provides students with a basic understanding of the challenges
faced by engineers and designers when designing a pharmaceutical manufacturing facility. The course will focus on the sterile manufacturing facility design model, although many of the principles discussed will apply to all other types of Pharmaceutical facilities. Pharmaceutical facilities are required to meet Good Manufacturing Practices (GMP) regulations, while at the same time, must be in compliance with all governing codes, laws and regulations. The main objective of the course is to provide students with a solid understanding of the key principles of facility design. The course blends practical applications, with the underlying theory behind basic concepts, so that the student obtains a balanced understanding of the topics. The course is intended to 1) teach students the basics of facility design, 2) highlight the major challenges faced by designers and engineers, 3) provide helpful dos and donts concerning design options, and 4) present important operational, testing and construction considerations that impact design decisions.
Course Requirements: Examination: Two exams, i.e. a midterm exam and a final exam Quizzes: Four quizzes as scheduled by instructor Grading Policy: Midterm exam..............................30% Final exam....................................30% Quizzes.........................................40% (10% each quiz) Course Final Grade: a tentative guideline for the assignment of final grades is provided below:
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Cumulative Points 90-100% 88-89% 80-87% 78-79% 70-77% <69%
Overall Grade A B+ B C+ C F
The grade of D is not assigned to students taking graduate courses. Please remember that this is only a guideline designed to help the students understand how they are performing in the course. Exams: A calendar of the exams is included in the Course Outline given below; All exams are typically 3 hours long unless otherwise stated; All exams are open book and open notes, unless otherwise announced; The final exam will include all material covered throughout the course (although the main emphasis of the exam may be on the material covered after the midterm exam); Make-up exams will only be given to students who cannot attend the regular exam time, and only under documented and extraordinary circumstances. In any case, no student will be allowed to a take a make-up exam unless he/she has the prior consent of the instructor. If a student fails to take an exam as scheduled, the exam grade will automatically be zero. Quizzes: A calendar of the quizzes is included in the Course Outline below. Quizzes are typically 1 hour long unless otherwise stated. Quizzes may be open or closed book and notes. Format will be announced. Quizzes will typically cover material from immediately preceding classes. Make-up quizzes will only be given if approved in advance for documented and extraordinary circumstances.
PhEn602-Pharmaceutical Facility Design-Spring 2009
Class Attendance: As for all graduate courses at NJIT, attendance is not mandatory, but strongly recommended. Experience shows that students who do not regularly attend class typically perform poorly in the course. In addition, discussions and material provided by any guest lecturers will not be covered in the notes. In any case, students are responsible for all material covered in class. Interwise access is anticipated for students unable to attend class in person due to travel or other business related activities. Details for accessing Interwise will be provided at the first class session.
PhEn602-Pharmaceutical Facility Design-Spring 2009
Important Dates on the NJIT Calendar (Spring 2009) visit NJITs website
01/21/09 02/02/09 Ck. Registrar 03/18/09 03/30/09 04/29/09 05/06/09 05/13/09 05/14/09 First Class PhEn-602 Section 102 Last Day for a Refund Based Upon A Partial Withdrawal Last Day for a Refund Based Upon a Complete Withdrawal No Class Spring Break Last Day to Withdraw from Course(s) (No Refund) Last Class-PhEn-602-102 Reading Day Final Exam PhEn-601 (Finals 12/15-19/08) Grades Due in Registrars Office
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PHARMACEUTICAL FACILITY DESIGN (PhEn-602) Wk #1 (1/21) Introduction & Planning A) GMPs, CFR, FDA B) Project planning Design Considerations A) Regulations B) Building & Zoning Codes C) Support Utility Requirements D) Bldg. Materials & Finishes E) Safety Types of Manufacturing A) Sterile / Aseptic B) Non-Sterile C) Liquid vs Dry D) Cross-Contamination E) Cleaning F) Single vs Multiple Products Quiz #1 (Tentative) Classified Spaces & Controlled Environments A) Clean Rooms B) ISO vs FSA C) Air Flow D) Exchange Rates Environmental Issues & Monitoring A) Microbial. B) Air & Liquid Discharge Quiz #2 (Tentative) Architectural A) Materials & Finishes B) Service / Maintenance a. Interstitial & Mech. Rooms
Wk #2 (1/28)
Wk #3 (2/04)
Wk #4 (2/11)
Wk #5 (2/18)
Wk #6 (2/25)
PhEn602-Pharmaceutical Facility Design-Spring 2009
Wk #7 (03/04) Wk #8 (03/11)
Midterm Examination Heating & Ventilation A) Equipment B) Configuration Air Conditioning A) Equipment B) Configuration Quiz #3 (Tentative) Moisture A) Humidification / Dehumidification B) Related Problems Utility Sizing A) Heating & Cooling Loads B) Psychometrics Critical Utilities A) Water B) Steam C) Gases Quiz #4 (Tentative) Layout A) Adjacencies B) Materials Flow C) Personnel Flow Semester Review Final Examination
Wk #9 (03/25)
Wk #10 (04/01)
Wk #11 (04/08)
Wk #12 (04/15)
Wk #13 (04/22)
Wk #14 (04/29) Wk #15 (05/13)
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Course Notes, Textbooks, and Other Reference Material: Notes: Pharmaceutical Facility Design Course Notes. These notes are duplications of the presentations used in class. The Notes will be posted on the NJIT website: Textbook: (Optional) International Society for Pharmaceutical Engineering,; Pharmaceutical Engineering Guides for New and Renovated Facilities, Volume 3, Sterile Manufacturing Facilities. Additional reference books are listed under references. Reference material: 1. International Society for Pharmaceutical Engineering, Pharmaceutical Engineering Guides for New and Renovated Facilities, Volume 3, Sterile Manufacturing Facilities, (textbook). 2. Sterile Product Facility Design and Project Management, 2nd edition, Jeffery N. Odum, CRC Press. 3. Good Design Practices for GMP Pharmaceutical Facilities, Andrew Signore and Terry Jacobs, Taylor and Francis 4. Aseptic Pharmaceutical Manufacturing, Applications for the 1990s, Groves and Murty, Interpharm Press 5. Validation of Pharmaceutical Processes, Carlton and Agalloco, Marcell Dekker, Inc. 6. Cleanroom Technology, Fundamentals of Design, Testing and Operation, Whyte, John Wiley 7. Cleanroom Microbiology for the Non-Microbiologist, Carlberg, Interpharm Press 8. International Society for Pharmaceutical Engineering; Pharmaceutical Engineering Guides for New and Renovated Facilities, Volume 4, Water and Steam Systems 9. International Society for Pharmaceutical Engineering; Pharmaceutical Engineering Guides for New and Renovated Facilities, Volume 5, Commissioning and Qualification
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http://web.njit.edu/~armenant/PhEn602-102
ISPE Guides
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ISPE
Excellent Resource
Publications: Guides, PE, JPI Networking COPs (Community of Practice) Educational Programs Student Programs
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Class Notes Notes can be found at:
http://web.njit.edu/~armenant/PhEn602-102
THIS ADDRESS IS CASE SENSITIVE
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Housekeeping
The email address listed with the official class roster will be used as needed to communicate with the class. Check this regularly, especially during periods of inclement weather Guest lecturers &/or tours may be scheduled as available and class schedule adjusted accordingly.
Novartis Tour 2/25/09
Text is optional and will not impact performance 30 Minute Policy for instructor absence Class Breaks will be discussed and a format selected, however this will remain at the instructors discretion.
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Library Research
http://www.library.njit.edu/stafffolders/slutsky/PharmTutorial/ Pharmtutorial.html Important Announcement for Users of Scifinder Scholar - The Web version became available to NJIT on January 20, 2009
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March 17-19, 2009 (Spring Break) Jacob K. Javits Center New York, NY
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PhEn-602 Pharmaceutical Facility Design
Week 1 GMPs Project Approach Design and Validation
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Pharmaceutical Facility Design
Good Manufacturing Practice (GMPs)
Food, Drug and Cosmetic act gives FDA authority to enforce legal requirements in manufacturing, processing, packing and holding of drugs. These requirements are found in
21CFR Part 211 Subpart C relates to Buildings and Facilities
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21 CFR Part 211 - Subpart C-Buildings and Facilities
211.42 Design and construction features. (a) Any building or buildings used in the manufacture, processing, packing, or holding of a drug product shall be of suitable size, construction and location to facilitate cleaning, maintenance, and proper operations. (b) Any such building shall have adequate space for the orderly placement of equipment and materials to prevent mixups between different components, drug product containers, closures, labeling, in-process materials, or drug products, and to prevent contamination. The flow of components, drug product containers, closures, labeling, in-process materials, and drug products through the building or buildings shall be designed to prevent contamination. (c) Operations shall be performed within specifically defined areas of adequate size.
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Pharmaceutical Facility Design
21 CFR Part 211 - Subpart C-Buildings and Facilities 211.42 Design and construction features.
There shall be separate or defined areas for the firm's operations to prevent contamination or mixups during: (1) Receipt, identification, storage, and withholding from use of components, drug product containers, closures, and labeling, pending the appropriate sampling, testing, or examination by the quality control unit before release for manufacturing or packaging; (2) Holding rejected components, drug product containers, closures, and labeling before disposition: (3) Storage of released components, drug product containers, closures, and labeling; (4) Storage of in-process materials; (5) Manufacturing and processing operations; (6) Packaging and labeling operations;
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Pharmaceutical Facility Design
21 CFR Part 211 - Subpart C-Buildings and Facilities 211.42 Design and construction features (cont).
(7) Quarantine storage before release of drug products; (8) Storage of drug products after release; (9) Control and laboratory operations; (10) Aseptic processing, which includes as appropriate: (i) Floors, walls, and ceilings of smooth, hard surfaces that are easily cleanable; (ii) Temperature and humidity controls; (iii) An air supply filtered through high-efficiency particulate air filters under positive pressure, regardless of whether flow is laminar or nonlaminar; (iv) A system for monitoring environmental conditions; (v) A system for cleaning and disinfecting the room and equipment to produce aseptic conditions; (vi) A system for maintaining any equipment used to control the aseptic conditions.
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Pharmaceutical Facility Design
21 CFR Part 211 - Subpart C-Buildings and Facilities 211.42 Design and construction features.
(d) Operations relating to the manufacture, processing, and packing of penicillin shall be performed in facilities separate from those used for other drug products for human use
Pharmaceutical Facility Design
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Pharmaceutical Facility Design Note:
The GMP Regulations specify what a particular requirement is (i.e. what is to be controlled), not how that requirement is to be achieved.
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What does FDA look for in a facility?
1)
Buildings and Facilities
2) 3) 4) 5) 6) 7) 8)
Is the facility suitable for the operations being carried out? Is the facility readily cleanable? Are there proper controls against cross-contamination? Is there adequate ventilation while still keeping out sources of contamination? Are there adequate sanitary facilities? Are there operational areas separate to prevent mixups and cross-contamination? What is the source of the water supply? Are there adequate systems for the handling and disposal of waste?
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What does FDA look for in a facility?
Materials handling and storage
1) 2) 3) 4) 5) Is there proper segregation between incoming and released components? Are environmental factors, such as temperature and humidity, monitored and controlled properly? Is there adequate storage space under the required environmental conditions? Are in-process materials properly stored? Are containers suitable for raw materials and intermediate product?
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What does FDA look for in a facility?
Equipment
1) 2) 3) 4) 5) Is the facility equipment suitable for its intended use? Is equipment designed to facilitate cleaning? Are there proper filtration systems adequately designed and properly functioning? Does equipment design prevent contamination from external sources? Is equipment clearly and uniquely identified?
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Pharmaceutical Facility Design
Pharmaceutical Facility Project Sequence
Design Good Engineering Practice Validation
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Pharmaceutical Facility Design
There must be a compelling reason for pursuing a new or renovated facility.
Sales of existing products have surpassed the capabilities of the current facility and an expansion is necessary. New products have been identified which require different types of facilities. Existing facility does not meet current regulatory requirements (e.g. FDA, EPA or other agency)
From J. Odum, Sterile Product Facility Design and Project Management
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Pharmaceutical Facility Design
There must be a compelling reason for pursuing a new or renovated facility.
Economic or business advantage associated with relocation to a new or existing site.
Improved labor pool Cost of upgrade, renovation, or change Cost of manufacturing and/or shipping Tax incentive Lower labor rate Reduced cost of employee benefits Not From J. Odum, Sterile Product Facility Design and Project Management
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Pharmaceutical Facility Design
Establish Goals Prepare the Business Case
From the business case we develop a plan for manufacturing, and then proceed into the Facility Planning stage
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Facility Planning is Critical
Exceptional facilities dont just happenthey are planned to be functional, efficient, cost effective, and compliant to all regulations. They are planned to meet market demands for productto be environmentally pleasing to those that work in them on a daily basisand they are planned to be safe, protecting the workers and the outside environment.
From J. Odum, Sterile Product Facility Design and Project Management.
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Facility Planning is Critical
Proper planning is the key..having a sound project management process is crucial In order to properly plan the facility, a significant amount of information is needed, such as project goals and objectives, product volumes, schedule, budget costs, utility requirements, safety requirements, etc., etc. This information is typically gathered during the facility programming portion of the conceptual design phase.
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Pharmaceutical Facility Design
Project Approach 9 stages
1. 2. 3. 4. 5. 6. 7. 8. 9.
Conceptual Study Functional Design/Preliminary Engineering Request for Funds Approved Detailed Engineering Procurement/Bidding Construction Commissioning Validation/Qualification Turnover to Owner
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Pharmaceutical Facility Design
PhEn-602 will focus on:
Design (1,2 & 4) Commissioning, Validation/Qualification(7 & 8)
1. 2. 3. 4. 5. 6. 7. 8. 9.
Conceptual Study Functional Design/Preliminary Engineering Request for Funds Approved Detailed Engineering Procurement Construction Commissioning Validation/Qualification Turnover to Owner
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Facility Programming
Business Objectives
Pharmaceutical Facility Design
Three phases to the Design Process
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Conceptual Design-Basic Elements
Establish goals and objectives, and discuss how GMP requirements will be met Conduct facility programming, with extensive data gathering - Very important! Conceptual layout and Accommodation Schedule Prepare Basis of Design (statement of criteria) Establish design philosophy: e.g. state-of-the-art or leading edge? Heating, Ventilation and Air-Conditioning philosophy Major equipment list Budget estimate (often prepared for management review)
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Conceptual Design Facility Programming
Process Packaging Preliminary Program Single Level Manuf./Pkg. Facility with Mezzanine - Office / Amenities - General Support Company Z - Laboratory
Manufacturing Admin
General Admin - Office General Admin Workstation Engineering - Office Engineering Workstation Purchasing - Office Purchasing - Workstation Health, Safety & Environ. - Office Maintenance - Office Production Planning Office Support Areas 120 64 120 64 120 64 120 120 120 150 5 3 10 20 3 3 2 6 3 55 600 192 1,200 1,280 360 192 240 720 360 8,250 8 4 16 30 4 4 2 10 4 82 960 256 1,920 1,920 480 256 240 1,200 480 12,300 Includes break areas, conference rooms, storage rooms, etc.
Functional Unit Title/ Space Description PROCESS Manufacturing Pharmacy Drying Blending Compression Encapsulation Coating
Unit Area Net SF
2008 No. of Units Total Area Net SF
2013 No. of Units Total Area Net SF Remarks
120 400 300 480 480 400
4 3 9 13 2 5
480 1,200 2,700 6,240 960 2,000
6 4 10 13 2 6
720 1,600 3,000 6,240 960 2,400
Manufacturing Admin SUBTOTAL - NSF General Support Manufacturing
Warehouse - Unreleased Material Warehouse - Released Material Warehouse Manufacturing WIP Technical Services Maintenance Shop Consumable Storage Filter Storage Chemical Dispensing Waste Drum Storage 6.00 6.00 6.00 5,927 5,000 1,200 1,200 450 200 1168 1067 718 1 1 1 1 1 1
8,250
12,300
Dirty Equipment Staging Equipment Wash Clean Equipment Storage Turret/Tooling Maintenance Tool Storage Tool Inspection Instrumentation Shop In-Process Test Solution Prep QA Sampling Men's Lockers Women's Lockers
600 600 1,200 600
1 1 1 1
600 600 1,200 600
1 1 1 1
600 600 1,200 600
7,008 6,402 4,308 5,927 5,000 1,200 1,200 450 200
1756 1604 1080 1 1 1 1 1 1
10,536 9,624 6,480 5,927 5,000 1,200 1,200 450 200
400 400 300 250 450 120 12 12
1 1 1 1 1 1 80 80
400 400 300 250 450 120 960 960
1 1 1 1 1 1 100 100
400 400 300 250 450 120 1,200 1,200
Includes toilets, sinks and showers. Based on two shifts. Includes toilets, sinks and showers. Based on two shifts.
Manufacturing Process SUBTOTAL NSF
20,420
22,240
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Conceptual Design Basic Elements:
Accommodation Schedule also called Bubble Diagram 2) Defines adjacencies and high level flow of material and personnel 3) Performed prior to layout of area
1)
EXTERNAL AREA
Factory Change
CORRIDOR
Personnel Clean Change
Equipment Airlock
Preparation Area Aseptic Change/ Gown
AUTOCLAVE
ASEPTIC CORE
INSPECTION & SECONDARY PACKAGING
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Functional Design Basic Elements
Also called: Preliminary Engineering, Front-end Design, Design Development
Establish a basis for detailed design
Prepare Basis of Design (BOD)
Layout of production lines, location of equipt., building services/utilities defined Create process specifications, process flow diagrams, and P&IDs (Process and Instrumentation Diagrams) Detailed cost estimate is generated Develop User Requirements Specifications (URS)
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Detailed Design
Prepare detailed engineering drawings to be issued for construction Create detailed equipments lists and instrument lists Develop construction strategy Set the basis for the Installation Qualification (IQ) Finalize layouts, size and routing of utilities
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Pharmaceutical Facility Design
Note: A more developed design produces a more accurate estimate! Too often projects are estimated at the conceptual design stage. Tip: If possible finish the functional design (preliminary engineering) before requesting funds to minimize submission of budget revisions.
Conceptual Design
Preliminary Engineering
Capital Funds Approval Request
Detailed Design PhEn602-Pharmaceutical Facility Design-Spring 2009
Capital Fund Request Reviewed & Approved 42
Good Engineering Practice
Established engineering methods and standards that are applied throughout the project lifecycle to deliver appropriate cost-effective solutionsincluding:
Professional and competent project management Professional and competent engineering design, procurement, construction and commissioning Full consideration of applicable safety, health and environmental statutory requirements Full consideration of operation and maintenance requirements Full consideration of recognized standards and guidance Appropriate documentation for ongoing operation and maintenance, and to demonstrate compliance with applicable regulations and codes
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Commissioning
A well planned, documented and managed engineering approach to the start-up and turnover of facilities, systems, and equipment to the End-User that results in a safe and functional environment that meets established design requirements and stakeholder expectations.
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Commissioning Plan
Prepared and approved by Commissioning Team Approvers include Construction, Design, Quality, Validation and User Department Representatives. Includes list of systems and equipment to be commissioned, including process equipment and utilities. Can include schedule/timeline for the commissioning activities Often precedes validation ETOP (Engineering Turn-Over Package) is often a deliverable.
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Commissioning Benefits
Can streamline the validation, since thorough up-front testing is done to eliminate bugs Improved documentation in place prior to IQ can reduce IQ execution effort Provides a formal structured approach to testing and owner acceptance, ensuring a minimum level of acceptable documentation Provides a formal structured approach to testing and acceptance, for those systems that are not validated (non-GMP).
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Validation An Essential Part of GMP
Validation is the scientific study of a system:
To prove that the facility system/equipment is consistently doing what it is supposed to do (i.e., that the process is under control) To determine the process variables and acceptable limits for these variables, and to set-up appropriate in-process controls. Validation as defined by FDA:
Establishing documented evidence which provides a high degree of assurance that a specific process will consistently produce a product meeting its predetermined specifications and quality attributes.
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Validation Execution-Three primary elements
DQ Design Qualification
Verifies the design is suitable/appropriate and will work
IQ - Installation Qualification
Verifies the system/equipment is supplied and installed correctly
OQ Operational Qualification
Verifies that the system/equipment operates as specified, intended throughout all anticipated ranges
PQ Performance Qualification
Verifies that the system/equipment performs as intended meeting predetermined acceptance criteria
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When to begin planning?
Validation needs must be incorporated in earliest stages of the project (DQ?) Should be considered during the design phase (DQ?) Validation cannot be thought of as the last hurdle. Ignoring validation early in the project will be disastrous!
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Project Validation Plan
Defines overall validation approach Defines validation activities to be performed; at a high level Defines roles and responsibilities Describes the phases to the validation effort Provides estimated timelines Must be approved by cross-functional team, with final approval by QA
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The V-Model
User Requirements Specification (URS) Related to Performance Qualification
Functional Specification
Related to
Operational Qualification
to
Detailed Design
Re la te
Related to
Installation Qualification
Implement/Build
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User Requirements Specification (URS)
Also called User Requirement Brief Describes what the system or equipment is supposed to do. Often sent to suppliers as part of the vendor solicitation process. Includes essential requirements (musts) as well as desirable requirements (wants) Normally written by user department, or engineer
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Functional Specification (FS)
Often written by supplier Describes what the system will do. Detailed functions are described. Links to an OQ, which tests all functions specified. The FS is a design output.
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Detailed Design Specifications (DDS)
Documents how the system will be built Like FS, is a design output Links to both IQ and OQ Based upon the detail design documents
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Quality Plan
A document setting out the specific quality practices, resources, and sequence of activities relevant to a particular product or process. It defines the general distribution of responsibilities for quality related tasks and the implementation of the Quality System elements
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Project Planning & Schedule
Agreed by team members Details phases, activities, and milestones Gantt Chart most commonly used
Task Name
Design Prepare Quality Plan Prepare URS Prepare Project Justification Document Obtain Funding Construct Commission Validate Turnover - Project Complete
Jan 2003 Feb 2003 2/9 2/16 2/23 3/2 Mar 2003 Apr 2003 May 2003
ID 1 2 3 4 5 6 7 8 9
Start 1/13/03 2/3/03 2/17/03 2/24/03 3/24/03 3/31/03 4/21/03 5/23/03 6/6/03
Finish 1/31/03 2/14/03 2/21/03 3/21/03 3/28/03 4/18/03 5/2/03 6/5/03 6/6/03
Duration
1/12 1/19 1/26 2/2 3/9 3/16 3/23 3/30 4/6 4/13 4/20 4/27 5/4 5/11
15d 10d 5d 20d 5d 15d 10d 10d 1d
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Putting it all together
Val id
atio n
c u tan al T Fin Accep and
PQrnover e
The Compliance Pyramid
Qu alif ica
ti o n
tion ic a alif cation Qu f i tion uali alla nal Q t Ins ratio pe O
IQ OQ
Com
mis sio nin g
ts Tes s tion est unc nce T F ta ls lity abi Accep anua er y M Op tor on ac perati F O
Good Engineering Practice
Des ign P
has e
n atio ific Plan pec on ts S lidati n Va me uire roject lan w q vie P P Re ns ser Plan roject MP Re ficatio U ty P /G ns eci ali nce n Sp icatio Qu lia sig f p ci Comnal De n Spe s ig tio unc tail De F De
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Project Life Cycle Discussion
Who are the players that make everything happen?
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The Project Team (Typical)
Project Leader
Stakeholders
Validation Team Rep Name Title Name Title Name Title
Quality Assurance Rep
Manufacturing Rep Name Title
Facilities and M aintenance Rep Name Title Name Title
Design Team Rep A/E Firm
Architect
Construction Group Rep
Quality Control Rep
Purchasing Rep
Finance Rep
M EP Supervisor Planner/ Scheduler
M echanical
Electrical
Purchasing
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Pharmaceutical Facility Design
Some unique aspects of Pharmaceutical Facility Projects
Plants are very expensive to build, as compared to other industries. Procurement costs for process equipment are astronomicalcan be 30% of overall project cost. Validation costs are very high,in some cases 1520% of overall project cost. Very long timelines from start to finish, often due to two major issues:
Specialty equipment lead-time Validation is extensiveup to 1 3 years in some cases, depending on size of project .
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Pharmaceutical Facility Design
Summary:
A structured project approach is required for successful implementation of Pharmaceutical Facility Projects A phased approach to the design is often used Good Engineering Practice and Commissioning play a key role in the project life-cycle Validation is an essential part of the facility system and must be considered at the earliest part of the project; during the design phase.
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Documentation Golden Rules
If there is no documentation; the job wasnt done That which is written remains
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Six Phases of a Project:
1) Enthusiasm 2) Disillusionment 3) Panic 4) Search for the guilty 5) Punishment of the innocent 6) Praise and honors for nonparticipants
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