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GMP compliance
By:
J.Ramniwas
Director-Regulatory and Quality Affairs
Pharmaocean,Vadodara(India)
1
Objective
2
Purpose of Documentation
Currency of corporation
4
Quality Policy and its Importance
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
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Quality Manual
6
Design of Documents
Useful
Flexible
Grow
Change
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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
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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.
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A Well Designed Documentation
System
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Manufacturer's Role
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Principles of Good Documentation
The heart of GMP is the establishment of well written procedures for each
step of our quality operations
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Proof of Quality
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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
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Basics of Record Keeping
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Real Time Formats and Dates
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Calculation and Numbers
e.g. 1+4 =5
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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
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Documentation Practices
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Documentation Practices
e filled in later
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Control of Records
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Electronic /Computerized Records
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GMP Numbering System
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SOP Numbers
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Lot Numbers
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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
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Document Numbers
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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
Ê Stock control and distribution records
Other documents …
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Standard Operating Procedures
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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
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How to write good SOPs
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Specifications and Test Procedures
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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
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Process Development Report
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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
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Production Record Review
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Packaging Instructions
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Equipment Records
Usage logs
Maintenance
sequence
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Laboratory Glassware
Product : ABC
Lot Number : 130
Sample :#1
Analyst initial & Date :
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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
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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.
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Laboratory Data
All raw data are kept with the test reports, unless there are
electronic records or other means of recording
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Out of Specification and Re-testing
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Data Review
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Stability Records
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Deviation Records
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Change Control Records
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Training Records
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Organisation Charts
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Job Description
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Technology Transfer Documents
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Validation Documentation
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Management Review Minutes
Attendance
Meeting Dates and Frequency
Discussions of Quality trends and issues
• Identify responsible person(s) for CAPA
• Target dates for actions
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Documents involved External Stake Holders
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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
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Complaints
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Product Recalls
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Health and Hygiene Records
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Pest and Rodent Control Records
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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.
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Stock Control and Distribution Records
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Design a Good Documentation System
services.
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Revision and Renewal of Documents
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