Quality Assurance & Quality Control In Pharma Industry

1. Quality Assurance& Quality Control In Pharma Industry Dr. Basavaraj K. NanjwadeM.Pharm., Ph. D Associate Professor of Pharmaceutics Department of Pharmaceutics KLE University, Belgaum – 590010, Karnataka, INDIA E-mail: bknanjwade@yahoo.co.in Cell No: 00919742431000

2. QA GMP QC

3. QA It is the sum total of the organized arrangements with the objective of ensuring that products will be of the quality required for their intended use

4. Is that part of Quality Assurance aimed at ensuring that products are consistently manufactured to a quality appropriate to their intended use GMP

5. QC Is that part of GMP concerned with sampling, specification & testing, documentation & release procedures which ensure that the necessary & relevant tests are performed & the product is released for use only after ascertaining it’s quality

6. QC is that part of GMP which is concerned with sampling, specifications, testing and with in the organization, documentation,and release procedures which ensure that the necessary and relevant tests are carried out QA and QC • QA is the sum total of organized arrangements made with the object of ensuring that product will be of the Quality required by their intended use.

7. Operational laboratory techniques and activities used to fulfill the requirement of Quality QA and QC • All those planned or systematic actions necessary to provide adequate confidence that a product will satisfy the requirements for quality

8. QC is lab based QA and QC • QA is company based

9. ESTABLISHING ACCEPTANCE CRITERION FOR A SPECIFIED IMPURITY IN A NEW DRUG SUBSTANCE Determine impurity level in relevant batches1 Isimpurity alsoa degradationproduct? YES Estimate maximum increase in impurityat retest date using data from relevantaccelerated and long-term stability studies Determine mean + upper confidence limit for the impurity (Let this = A) NO IsA or B greater than thequalifiedlevel? Acceptance criterion = A or B(as appropriate) Determine maximum likely level as:A + increase in degradation product atappropriate storage conditions.(Let this = B) NO YES 1Relevant batches are those from development, pilot and scale-up studies. 2 Refer to ICH Guideline on Impurities in New Drug SubstancesDefinition: upper confidence limit = three times the standard deviation of batch analysis data Acceptance criterion = qualified levelor establish new qualified level2

10. ESTABLISHING ACCEPTANCE CRITERION FOR A DEGRADATION PRODUCT IN A NEW DRUG PRODUCT Doesdegradationoccur during productmanufacture? Estimate maximum increase in degradation product at shelf life usingdata from relevant accelerated andlong-term stability studies. (Let this = D) NO YES Determine maximum likely level as drug substance acceptance criterion2.((A or B)+ C + D) Estimate maximum increase in degradationproduct during manufacture from relevantbatches1. (Let this = C) Ismaximum likely level greaterthan thequalifiedlevel? NO Acceptance criterion = maximum likely level. YES Acceptance criterion = qualified levelor establish new qualified level3or new storage conditions or reduce shelf life. 1 Relevant batches are those from development, pilot and scale-up studies.2 Refer to Decision Tree 1 for information regarding A and B.3 Refer to ICH Guideline on Impurities in New Drug Products.

11. SETTING ACCEPTANCE CRITERIA FOR DRUG SUBSTANCE PARTICLE SIZE DISTRIBUTION No drug substance particlesize acceptance criterion required for solution dosage forms. Is the drug product a soliddosage form or liquid containing undissolveddrug substance? NO YES 1. Is the particle size critical to dissolution, solubility, or bioavailability?2. Is the particle size critical to drug product processability?3. Is the particle size critical to drug product stability?4. Is the particle size critical to drug product content uniformity? 5. Is particle size critical for maintaining product appearance? If NO to all If YES to any No Acceptance Criterion Required Set Acceptance Criterion

12. INVESTIGATING THE NEED TO SET ACCEPTANCE CRITERIA FOR POLYMORPHISMIN DRUG SUBSTANCES AND DRUG PRODUCTS Drug Substance Candifferent polymorphsbe formed? NO Conduct polymorphismscreen on drug substance. 1. No further action YES Characterize the forms:e.g., - X-ray Powder Diffraction - DSC / Thermoanalysis - Microscopy - Spectroscopy 2. GO TO

13. INVESTIGATING THE NEED TO SET ACCEPTANCE CRITERIA FOR POLYMORPHISMIN DRUG SUBSTANCES AND DRUG PRODUCTS 2. Do theforms havedifferent properties?(solubility, stability,melting point) NO No further test oracceptance criterionfor drug substance YES Is drugproduct safety,performance or efficacy affected? NO YES Set acceptance criterionfor polymorph contentin drug substance 3. GO TO

14. INVESTIGATING THE NEED TO SET ACCEPTANCE CRITERIA FOR POLYMORPHISMIN DRUG SUBSTANCES AND DRUG PRODUCTS Drug Product - Solid Dosage Form or Liquid Containing Undissolved Drug Substance Undertake the following processes only if technically possibleto measure polymorph content in the drug product. 3. Doesdrug productperformance testingprovide adequate control if polymorph ratio changes(e.g., dissolution)? Establish acceptance criteriafor the relevant performance test(s). YES NO Monitor polymorph form duringstability of drug product. Does achange occurwhich could affect safety or efficacy? NO No need to set acceptance criteriafor polymorph change in drug product. YES Establish acceptance criteriawhich are consistent with safety and/or efficacy.

15. ESTABLISHING IDENTITY, ASSAY AND ENANTIOMERIC IMPURITY PROCEDURES FOR CHIRAL NEW DRUG SUBSTANCES AND NEW DRUG PRODUCTS CONTAINING CHIRAL DRUG SUBSTANCES Consider the need forverifying chiral identity indrug substance releaseand/or acceptance testing. Chiral identity, assay and impurity procedures are not needed. YES Is the newdrug substancechiral1? NO AND RACEMIC YESAND ONE ENANTIOMER Needed for drug substance specification:2 -chiral identity3 -chiral assay4 -enantiomeric impurity5Needed for drug product specification6: -chiral assay4 -enantiomeric impurity5 1 Chiral substances of natural origin are not addressed in this Guideline. 2 As with other impurities arising in and from raw materials used in drug substance synthesis, control of chiral quality could be established alternatively by applying limits to appropriate starting materials or intermediates when justified from developmental studies. This essentially will be the case when there are multiple chiral centers (e.g., three or more), or when control at a step prior to production of the final drug substance is desirable. 3 A chiral assay or an enantiomeric impurity procedure may be acceptable in lieu of a chiral identity procedure. 4 An achiral assay combined with a method for controlling the opposite enantiomer is acceptable in lieu of a chiral assay. 5 The level of the opposite enantiomer of the drug substance may be derived from chiral assay data or from a separate procedure. 6 Stereospecific testing of drug product may not be necessary if racemization has been demonstrated to be insignificant during drug product manufacture and during storage of the finished dosage form.

16. MICROBIOLOGICAL QUALITY ATTRIBUTES OF DRUGS SUBSTANCE AND EXCIPIENTS NO Is the drug substances/excipient Capable of supporting microbial Growth or viability Provide supporting data. Microbial Limits acceptance criteria and testing May not be necessary YES YES Is the drug substances/excipient Sterile? No further microbial limits testing or Acceptance criteria are necessary NO Establish microbial limit acceptance criteria As per the harmonized pharmacopeial monograph Does drug substances/excipient Synthesis/processing involve Steps which inherently Reduce microorganisms? YES NO Establish microbial limit acceptance Criteria As per the harmonized pharmacopoeial monograph Does scientific evidence demonstrate that Reducation steps result in microorganism levels <acceptance criteria limits (and the absence of Compendial indicator organisms) In the drug substance/excipient? Are monitoring Microorganism/indicator levels Consistently below acceptance criteria Levels? YES NO YES NO Provide supporting data. Microbial limits acceptace Criteria and testing May not be necessary Test lots on a skip-lot basis for Microbial limits and freedom from Compendial indicator organisms. Test each lot for microbial limits and freedom from compendial indicator organisms.

17. SETTING ACCEPTANCE CRITERIA FOR DRUG PRODUCT DISSOLUTION 1. What type of drug release acceptance criteria are appropriate? Is the dosageform designed to producemodified release? Establish drug release acceptance criteria.Extended release: multiple time pointsDelayed release: two stages, parallel or sequential YES NO Is drug solubilityat 37 ± 0.5°C high throughoutthe physiological pH range?(Dose/ solubility < 250 mL(pH 1.2 - 6.8)) NO YES Is dosage formdissolution rapid?(Dissolution > 80% in 15 minutesat pH 1.2, 4.0, and 6.8) NO Generally single-point dissolutionacceptance criteria with a lower limit are acceptable. YES NO Has a relationship beendetermined between disintegrationand dissolution? Generally disintegration acceptance criteria with an upper time limit are acceptable. YES Continued on next page.

18. SETTING ACCEPTANCE CRITERIA FOR DRUG PRODUCT DISSOLUTION What specific test conditions and acceptance criteria are appropriate? [immediate release] 2. Doesdissolution significantlyaffect bioavailability?(e.g., have relevant developmentalbatches exhibited unacceptablebioavailability?) Attempt to develop test conditions and acceptance criteria which can distinguish batches with unacceptable bioavailability. YES NO Do changes informulation ormanufacturing variables affect dissolution?(Use appropriate ranges.Evaluate dissolutionwithin pH 1.2 - 6.8) YES Are these changes controlledby another procedure and acceptancecriterion? YES NO NO Adopt appropriate test conditionsand acceptance criteria without regard to discriminating power, to pass clinically acceptable batches. Adopt test conditions and acceptance criteriawhich can distinguish these changes. Generally, single point acceptance criteria are acceptable.

19. SETTING ACCEPTANCE CRITERIA FOR DRUG PRODUCT DISSOLUTION 3. What are appropriate acceptance ranges? [extended release] Are bioavailabilitydata available for batcheswith different drug release rates? NO Is drug release independent ofin vitro test conditions? YES YES NO Can an in vitro / in vivorelationship be established?(Modify in vitro test conditionsif appropriate.) Use all available stability, clinical, andbioavailability data to establish appropriate acceptance ranges. NO YES Use the in vitro / in vivocorrelation, along withappropriate batch data, to establish acceptance ranges. Are acceptanceranges >20% of thelabeled content? Provide appropriatebioavailability datato validate theacceptance ranges. YES NO Finalize acceptance ranges.

20. MICROBIOLOGICAL ATTRIBUTES OF NON-STERILE DRUGS PRODUCTS YES No Does the drug product contain Antimicrobial preservatives or possess Inherent antimicrobial activity Establish preservative chemical acceptance criteria and Perform preservative effectiveness validation of product Containing less than or equal to the minimum specifie Preservative concentration, or demonstrate the inherent Antimicrobial activity of the drug product. Is the drug product a dry dosage form (e.g. solid oral or dry powder)? No YES Establish microbial limit acceptance criteria As per the harmonized pharmacopoeia Monograph. No Does scientific evidence demonstrate Growth inhibitory properties of the Drug product? Perform microbial limits testing on a Lot-by-lot basis. YES No Microbial limits acceptance criteria and testing May not be necessary Do production lots consistently meet Microbial limits acceptance criteria? YES Perform skip-lot testing for microbial Limits, or provide scientific justification for no routine microbial limits testing.

21. ICH Harmonised Tripartite Guideline • Stability Testing of New Drug Substances and Products • Stability Testing: Photostability Testing of New Drug Substances and Products • Stability Testing for New Dosage Forms • Bracketing and Matrixing Designs for Stability Testing of New Drug Substances and Products • Evaluation for Stability Data • Stability Data Package for Registration Applications in Climatic Zones III and IV • Validation of Analytical Procedures: Text and Methodology • Impurities In New Drug Substances

22. ICH Harmonised Tripartite Guideline • Impurities in New Drug Products • Impurities: Guideline forResidual Solvents • Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Microbiological Examination of Non-Sterile Products: Microbial Enumerations Tests • Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Microbiological Examination of Non-Sterile Products: Test for Specified Micro-Organisms

23. ICH Harmonised Tripartite Guideline • Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Microbiological Examination of Non-Sterile Products: Acceptance Criteria for Pharmaceutical Preparations and Substances for Pharmaceutical Use • Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Residue on Ignition/Sulphated Ash • Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Test for Extractable Volume of Parenteral Preparations

24. ICH Harmonised Tripartite Guideline • Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Test for Particulate Contamination: Sub-Visible Particles • Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Disintegration • Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Uniformity of Dosage Units • Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Region on Dissolution Test

25. ICH Harmonised Tripartite Guideline • Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Sterility Test • Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions onTablet Friability • Evaluation and Recommendation of Pharmacopoeial Texts for Use in the ICH Regions on Polyacrylamide Gel Electrophoresis • Viral Safety Evaluation of Biotechnology Products Derived from Cell Lines of Human or Animal Origin

26. ICH Harmonised Tripartite Guideline • Quality of Biotechnological Products: Analysis of the Expression Construct in Cells used for Production of r-DNA Derived Protein Products • Quality of Biotechnological Products: Stability Testing of Biotechnological/Biological Products • Derivation and Characterisation of Cell Substrates Used for Production of Biotechnological/Biological Products • Comparability of Biotechnological/Biological Products Subject to Changes in their Manufacturing Process • Specifications: Test Procedures and Acceptance Criteria for New Drug Substances and New Drug Products: Chemical Substances

27. ICH Harmonised Tripartite Guideline • Specifications: Test Procedures and Acceptance Criteria for Biotechnological/Biological Products • Good Manufacturing Practice Guide for Active Pharmaceutical Ingredients • Pharmaceutical Development • Quality Risk Management • Pharmaceutical Quality System • Quality Implementation Working Group

28. Quality Assurance (QA) Management Procedure

29. How to write Standard Operating Procedure • SOP describes standard SOP format that you can use immediately for your quality procedure. • SOP has instructions on how to write a formal operating procedure for your systems which your people can follow everyday.

30. All Documents-Classifications, Definition and Approval Matrix • In this SOP you will find all type of quality and Technical/Master file documents to build up a good quality management system for your manufacturing sites, definition of documents, their classification, approval requirements and retention requirements. • This procedure has schematic diagrams for your understanding of how different types of documents are prepared and stored in a typical documentation.

31. Quality Documentation Management and Change Control • This SOP describes how to generate new quality documents or change control of existing documents, review of quality documents, satellite file management, role of document author, approver, document control officer and satellite file administrator. • In this SOP you will also find numbering systems of different quality documents like audit files, SOP’s, forms, manuals, training files, QA agreements, project files etc and their effective archiving system.

32. Documentation Rule for GMP Documents • This SOP describes the principles to be followed in GMP documents, entry of data and information, signature requirements and correction technique of incorrectly entered data or information.

33. Quality Documentation-Control, Tracking and Distribution • In this SOP you will find mainly the role of document control officer during the initiation, creation, circulation and approval of new quality related documents. • It also describes the procedure of modification and review of existing document using a documentation database. • Management of existing and superseded documents is also a art of this procedure. • You will see all the forms referred during the instruction are attached at the end of the procedure.

34. Preparation, Maintenance and Change Control of Master Documents • This SOP particularly focused on the management of master file documents like specifications, control methods, raw materials, finished goods and packaging specification and test reports, formulation, stability files etc required to generate during the product registration in the market. • This SOP gives instruction on their creation, change control, numbering system, approval requirements and maintenance in a simple master file database. • You will see all the forms referred during the instruction are attached at the end of the procedure.

35. Deviation Report System • It is a regulatory requirement to capture all sorts of deviations evolves in your systems in order to maintain the continuous improvement to your processes and systems. • This SOP describes how to categorize the deviations between production, audit, quality improvements, technical deviations, customer complaints and environmental, health and safety deviations. • It describes the management responsibilities of initiating deviation, capture data, analysis, investigation, determination of assignable causes, generation of management report and initiatives to be taken on corrective and preventative actions.

36. Shelf Life of Product • This simple SOP describes the meaning of shelf life and provides on how to interpret shelf lives and storage conditions for your raw materials from the Certificate of Analysis, determining expiry date for your finished products by use of raw material date of manufacturing and their shelf lives.

37. Vendor Selection and Evaluation • This SOP describes the procedure to be followed during the vendor assessment and vendor evaluation for purchasing of raw materials, critical and non critical packaging components, laboratory supplies, engineering supplies and imported finished goods from the vendor. • These instructions are essential for approving prospective vendor.

38. Vendor Certification • This procedure aim to describe the process by which a vendor may be certified to supply materials or services. • This procedure applies to vendors that supply a material or service to be used at any stage of manufacture by operations. • Here you will get the roles of each department in the process to certify an approved vendor.

39. Product Complaint Procedure • This procedure covers the receipt, logging, evaluation, investigation and reporting system of all complaints received from customers for the marketed products. • This SOP contains step by step instruction to be followed in the customer complaint management like numbering of complaint, registration, evaluation of complaints, determination of assignable cause for the complaint deviation, implementation of corrective and preventive actions, trending of complaints and handling of counterfeit products.

40. Annual Product Review • This procedure provides a guideline to annual product review which is required to be performed for each product produced for the commercial market to evaluate data, trends and to identify any preventative or corrective action that would lead to product quality improvements and report them to management.

41. Rework Procedure • This SOP contains the step by step instruction to be followed when the rework of an in-process or completed finished good is required. • This SOP covers the reworks of in-process manufactured goods where new batch number is introduced for the reworked part and rework of manufactured finished good keeping the same batch number. • This SOP also describes how to create rework protocols for each individual case.

42. Authorized Person • This simple procedure describes the accreditation, accountabilities and responsibilities of an Authorized person, responsible for release of finished goods for sale.

43. Product Identification and Traceability • The purpose of this SOP is to define the method used for the identification of all contributing materials that could affect product quality and to ensure their full traceability. • Here you will find instruction on all the records and documents used for the identification and traceability of incoming raw materials and out going finished goods.

44. Audits • This SOP describes the process of planning, performing, reporting and follow-up of different audits for your systems like Internal Quality audit, Vendor audit, Environmental Health and Safety (EHS) audit, EHS workplace inspection, Housekeeping audit. • This SOP also describes the process to be followed by manufacturing personnel during an audit from a Regulatory authority.

45. Example-Checklist for Batch Documentation • This SOP describes the identification of all documentation relevant to a production process in the form of “Batch Documentation Checklists” and to ensure their collection by completion of the checklists by Authorized Persons. • This procedure is based on an example of tablet packaging process described in the ‘Manufacturing’ category.

46. Evaluation of Batch Documentation and Release for Sale • This procedure describes the process of collection, evaluation and record of batch related document generated during the production of a batch before an authorized person can release the batch for sale. • This procedure is based on an example of tablet packaging process described in the ‘Manufacturing’ category.

47. GMP Training • This SOP describes how to design and deliver GMP related training for your manufacturing staffs, training assessment design, recording of assessment and preparation of training reports.

48. How to Write Training Materials • This simple SOP contains instructions on how to write training materials, identification of training requirements, available resources, preparation of training aid checklists for your manufacturing staffs.

49. House Keeping Audit Procedure • This SOP describes the requirements, checklists and reporting procedure on housekeeping audits. • Individual checklist forms are attached at end of the procedure for different areas like process, laboratory, engineering stores, warehouses. • This procedure also describes the handling of non-compliance found during the housekeeping audits.

50. Management and Control of Contract Work • The procedure describes the management and control of contract work provided by the contractors for packaging and finished products for your company as well as control of contract works done by your company on behalf of others.