PROJECT
Transcription
PROJECT
INSTALLATION QUALIFICATION QUALIFICATION OPERATIONAL QUALIFICATION AND AND CYCLE DEVELOPMENT DEVELOPMENT P ##### © La Calhène 1997 MSD - MK 826 PROJECT STERILE ANTIBIOTIC FILLING Length Volume 8m 28 m 8m 27 m3 100 m3 34 m3 (including HVAC) FREEZE DRYERS LOADING/UNLOADING Stoppers Heating Tunnel TV Inspection Vials Filling Stoppering Sterilizer LYO 1 LYO 2 LYO 3 Capping LYO 4 Frames Washer Accumulation Frames recycling Conventional capping Transition P ##### 40108 © La Calhène 1997 All isolators are with recirculating laminar flow VHP sterilization (VHP 1000) Filling and freeze dryers interface isolators working at RH 15 % Surrounding room : Grade D Partners : BOSCH, USIFROID, SEIDENADER, IMA. P 692/B LA CALHENE VALIDATION DATION VALI ON VALIDATI DEPARTMENT - missions missions EXTERNAL SERVICES: On site qualification of special isolator systems example filling line isolator On site qualification of “standard “isolator systems - example sterility test suites On site qualification of auxiliary equipment example GLT,TLT, RTD Technical support for PQ On site post qualification training P ##### © La Calhène 1997 LA CALHENE VALIDATION DATION VALI VALIDATION DEPARTMENT (2) INTERNAL SERVICES: Qualification of La Calhène standard equipment DPTE BETA BAG, GLT, RDT, TLT, sterilizers sterilizers Validation support for sterile packaging facility Validation of sterilization of beta bag systems Development and qualification of Bis for confinement systems P ##### © La Calhène 1997 Q UALIFICATION PROTOCOLES ES QUALIFICATION ON PROTOCOL QUALIFICATI Protocols are prepared using an “industry standard” standard” format Sent to customer for approval at least 5 weeks prior to start of qualification P ##### © La Calhène 1997 INSTALLATION QUALIFICATION QUALIFICATION ((1) 1) ETUDES & DEVELOPPEM ENT V A L ID A T IO N 1 rue d u P e tit C l a m art - B .P . 5 0 78 14 2 V E L IZ Y C E D E X - F R A N C E T é l. 0 1.4 6.2 9.9 9.60 - F ax . 01.4 6.30.8 7.3 0 C N S C A 1 6 1 /1 6 1 /4 T E S T S G U ID E IQ N° TESTS P a ge R ev. P a ge 8 /4 9 C L C refer enc e : 37K 53E C u sto m er referen c e : 4 5 3 8 2 1 3 5/3 9 2 C u sto m er : M SD F IC H E S D E C O N T R O L E IN SP E C T IO N N O T E S N S C A 1 6 1/3 1 N° P ag e REF ERENCE DO CUM ENT V A L ID A T IO N M A N A G E R N am e 1 .0 D o c u m e n ta tio n re v ie w N S C A 1 6 1 /1 6 1 (1 /4 to 4 /4 ) 3 to 6 J. N O T T IN G H A M 2 .0 U tility c o n n e c tio n c h e c k N S C A 1 6 1 /1 6 2 (1 /1) 7 J. N O T T IN G H A M 3 .0 P & ID c h e c k 1. C om p on e n t a nd id en tifica tion ch e ck N S C A 1 6 1 /1 6 N /A N /A J. N O T T IN G H A M 2. C om p on e n t con form ity ch e ck N S C A 1 6 1 /1 6 3 (1 /15 to 1 5/1 5) 8 to 2 2 J. N O T T IN G H A M LA CALHENE IN S P E C T IO N S / T E S T S NAM E E x ecu ted b y V erified b y P ##### © La Calhène 1997 D A T E & V IS A D a te & V isa CUSTO M ER NAM E D A T E & V IS A INSTALLATION INSTALLATION QUALIFICATION QUALIFICATION ((2) 2) ETUDES & DEVELOPPEM ENT V A L ID A T IO N 1 ru e d u P e tit C l a m a r t - B .P . 5 0 78 14 2 V E L IZ Y C E D E X - F R A N C E T é l. 0 1 .4 6 . 2 9 .9 9 . 6 0 - F a x . 0 1 . 4 6 . 3 0 . 8 7 .3 0 C N S C A 1 6 1 /1 6 2 /4 T E S T S G U ID E IQ N° TESTS 4 .0 H A Z O P a n d S o co tec ch ec k 5 .0 E le c tr ic a l in s ta lla t io n c h e c k 6 .0 P age R ev. P age 9 /4 9 C L C refer enc e : 37K 53E C u s to m er refere n c e : 4 5 3 8 2 1 3 5 /3 9 2 C u s to m er : M SD F IC H E S D E C O N T R O L E IN S P E C T IO N N O T E S N S C A 1 6 1 /3 1 N° P age REFERENCE DO CUM ENT V A L ID A T IO N M A N A G E R N am e N S C A 1 6 1 /1 6 N /A N /A J . N O T T IN G H A M 5 .1 E le c tric a l c a b in e t c o m p o n e n t c h e c k E le c t r i c a l fi le N /A N /A J . N O T T IN G H A M 5 .2 C a b li n g c h e c k E le c t r i c a l fi le N /A N /A J . N O T T IN G H A M 5 .3 V a l v e a n d b l o w e r o p e ra ti o n N T A 3 0 1 4 /2 4 (1 / 2 t o 2 /2 ) 2 3 to 2 4 J . N O T T IN G H A M 5 .4 M u n ters N S C A 1 6 1 /1 6 N /A N /A J . N O T T IN G H A M N T A 3 0 1 4 /2 5 (1 /1 ) 25 J . N O T T IN G H A M N S C A 1 6 1 /1 6 N /A N /A J . N O T T IN G H A M D a te & V isa M e c h a n i c a l i n s t a ll a tio n c h e c k 6 .1 Is o l a t o r t r a n s f e r s y s t e m s 6 .2 A cce ss w in d o w s a n d d o o rs LA CALHENE IN S P E C T IO N S / T E S T S NAM E E x ecu ted b y V e rifie d b y P ##### © La Calhène 1997 D A T E & V IS A CUSTO M ER NAM E D A T E & V IS A INSTALLATION INSTALLATION QUALIFICATION QUALIFICATION ((3) 3) ETU D ES & D EV ELO PPEM EN T V A L ID A T IO N 1 r u e d u P e ti t C l a m a r t - B .P . 5 0 78 14 2 V E L IZ Y C E D E X - F R A N C E T é l. 0 1 .4 6 . 2 9 .9 9 . 6 0 - F a x . 0 1 . 4 6 . 3 0 . 8 7 .3 0 C N S C A 1 6 1 /1 6 3 /4 T E S T S G U ID E IQ N ° 7 .0 TESTS Page R ev. P age 1 0 /4 9 C L C reference : 37K 53E C u s to m er refere n c e : 4 5 3 8 2 1 3 5 /3 9 2 C u s to m er : M SD F IC H E S D E C O N T R O L E IN S P E C T IO N N O T E S N S C A 1 6 1 /3 1 N° P age REFERENCE DO C UM ENT V A L ID A T IO N M A N A G E R N am e D a te & V isa C a lib r a t i o n c h e c k 7 .1 R e l a t i v e h u m i d it y s e n s o r s N S C A 1 6 1 /1 6 6 26 J . N O T T IN G H A M 7 .2 D if f e r e n t i a l p r e s s u r e s w i t c h e s N S C A 1 6 1 /1 6 7 27 J . N O T T IN G H A M 7 .3 D if f e r e n t i a l p r e s s u r e s e n s o r s N S C A 1 6 1 /1 6 8 28 J . N O T T IN G H A M 7 .4 A ir v e l o c it y s e n s o r N S C A 1 6 1 /1 6 9 29 J . N O T T IN G H A M 7 .5 T e m p e r a tu r e s e n s o rs N S C A 1 6 1 /1 6 10 30 J . N O T T IN G H A M 7 .6 T h e rm o m e te rs N S C A 1 6 1 /1 6 11 31 J . N O T T IN G H A M 7 .7 T e m p e r a t u r e s w itc h e s ( h e a t t a p e c o n t r o l ) N S C A 1 6 1 /1 6 12 32 J . N O T T IN G H A M 7 .8 C on v e rte rs N S C A 1 6 1 /1 6 13 33 J . N O T T IN G H A M 7 .9 L o o p te s t N S C A 1 6 1 /1 6 14 34 J . N O T T IN G H A M N S C A 1 6 1 /1 6 15 35 J . N O T T IN G H A M 7 .1 0 P re s s u r e g a u g e s LA C A LH EN E IN S P E C T IO N S / T E S T S N A M E D A T E & V IS A C U STO M ER N A M E E x ecu ted b y V e rifie d b y 1 r u e d u P e ti t C l a m a r t - B .P . 5 0 78 14 2 V E L IZ Y C E D E X - F R A N C E T é l. 0 1 .4 6 . 2 9 .9 9 . 6 0 - F a x . 0 1 . 4 6 . 3 0 . 8 7 .3 0 P ##### © La Calhène 1997 ETU D ES & D EV ELO PPEM EN T V A L ID A T IO N D A T E & V IS A INSTALLATION INSTALLATION QUALIFICATION QUALIFICATION ((4) 4) ETUDES & DEVELO PPEM ENT V A L ID A T IO N 1 ru e d u P e tit C la m art - B .P . 5 0 78142 V E LIZY C E D E X - F R AN C E T é l. 0 1.4 6. 2 9 .9 9 .60 - F ax . 01 .4 6 .30 .8 7 .3 0 C N S C A 1 6 1 /1 6 4 /4 T E S T S G U ID E IQ N° 8 .0 TESTS R e v. P a g e 1 1 /4 9 C 37K 53E C u s to m er r ef er e n c e : 4 5 3 8 2 1 3 5/3 9 2 C u s to m er : M SD F IC H E S D E C O N T R O L E I N S P E C T IO N N O T E S N S C A 1 6 1/3 1 N° P age REFERENCE DO CUM ENT V A L ID A T IO N M A N A G E R N am e D a t e & V is a F u n c tio n a l te s ti n g o f c o n tr o l h a r d w a r e a n d s o ft w a r e 8 .1 H a r d w ar e ch e ck N S C A 1 6 1 /2 5 J . N O T T IN G H A M 8 .2 B a ck u p an d r es to re tes t N S C A 1 6 1 /2 5 J . N O T T IN G H A M 8 .3 L oa d e r a n d a p p lica tio n ve rifica tio n N S C A 1 6 1 /2 5 J . N O T T IN G H A M 8 .4 In p u t/o u tp u t tes ts N S C A 1 6 1 /2 5 J . N O T T IN G H A M 8 .5 U n ita r y te sts (fu n ctio n al b lo ck ) N S C A 1 6 1 /2 5 8 .6 T ra n s itio n t es ts N S C A 1 6 1 /2 5 J . N O T T IN G H A M 8 .7 S e q u en cin g te sts N S C A 1 6 1 /2 5 J . N O T T IN G H A M 8 .8 P ha se tes ts N S C A 1 6 1 /2 5 J . N O T T IN G H A M 8 .9 D e fa u lt tes tin g – s e co n d a ry n etw o r k N S C A 1 6 1 /2 5 J . N O T T IN G H A M N /A J . N O T T IN G H A M 8 .1 0 P ha se v ie w te sts NAM E E x e c u te d b y V e ri fie d b y © La Calhène 1997 N /A N /A J . N O T T IN G H A M LA CALHENE IN S P E C T IO N S / T E S T S P ##### P age L C r ef er e n c e : D A T E & V IS A CUSTO M ER NAM E D A T E & V ISA OPERATIONAL QUALIFICATION (1) ETUD ES & DEVELO PPEM ENT V A L ID A T IO N 1 rue d u P e tit C lam art - B .P . 5 0 78 14 2 V E LIZY C E D E X - F R AN C E T él. 0 1.4 6.2 9.9 9.60 - F ax . 01.4 6.30.8 7.3 0 C 1/2 TE STS G U ID E OQ N° TEST P RO C E D U R E T E ST S D oc N ° : N S C A 161/17 P age R ev. P age L C refer ence : 37K 53 E C ustom er reference : 453 8213 5/3 92 7/28 C ustom er : M SD B F IC H E S D E C O N T RO L E IN SP E C T IO N NO T E S N SC A 16 1/32 N° P ag e V A L ID A T IO N M A N AG E R Nam e 1.0 C h ec k o f IQ p rio r ity 1 p u n ch list c o m p letio n N SC A 1 61 /17 N /A N /A J. N O T T IN G H AM 2.0 F ilter in t eg r ity te stin g N T A 3 01 4/10 1 (1/13 to 1 3/1 3) 3 to 15 J. N O T T IN G H AM 3.0 L ea k test in g N T A 30 14 /6 2 (1/1) 16 J. N O T T IN G H AM 4.0 V H P 1001 fu n ction al ch ec k N T A 30 18 /1 3 (1/2 to 2 /2) 17 to 1 8 J. N O T T IN G H AM 5.0 S te riliza tio n p h a se te s t N SC A 1 61 /21 4 (1/4 to 4 /4) 19 to 2 2 J. N O T T IN G H AM 6.0 A ir d istrib u tio n Pressure differen tial in production ph ase N SC A 1 61 /10 5 (1/2 to 2 /2) 23 to 2 4 J. N O T T IN G H AM R ecircu lation rate in prod uction p hase N SC A 1 61 /10 6 (1/14 to 1 4/1 4) 25 to 3 8 J. N O T T IN G H AM 1.3. Air change rate in aeration step of sterilization p hase N SC A 1 61 /10 7 (1/3 to 3 /3) 39 to 4 1 J. N O T T IN G H AM 1.4. Air speed m ap, u niform ity of airflow sm oke test in prod uction p hase N T A 3 01 4/11 8 (1/8 to 8 /8) 42 to 4 9 J. N O T T IN G H AM 1.1. 1.2. an d LA CALHENE IN S P E C T IO N S / T E S T S NAM E V erified b y P ##### © La Calhène 1997 D A T E & V ISA D a te & Visa CUSTOM ER NAM E D A T E & V ISA OPERATIONAL QUALIFICATION (2) ETUDES & DEVELOPPEM ENT V A L ID A T IO N 1 rue d u P etit C lam art - B .P . 5 0 78 14 2 V E LIZY C E D E X - F R AN C E T é l. 0 1.4 6.2 9.9 9.60 - F ax . 01. 4 6. 30.8 7.3 0 C 2 /2 T E S T S G U ID E OQ N° T E ST S T E ST P RO C ED URE D oc N ° : N S C A 1 6 1 /1 7 P a ge R ev. P a ge L C refer enc e : 37 K 53 E C u sto m er referen c e : 45 38 21 3 5/39 2 8 /2 8 C u sto m er : M SD B F IC H E S D E C O N T R O L E IN SP E C T IO N N O T E S N S C A 1 6 1/32 N° P ag e V A L ID A T IO N M A N A G E R Nam e 7 .0 P a rtic le c o u n t N T A 3 0 1 4 /12 9 (1 /7 to 7 /7 ) 5 0 to 5 6 J. N O T T IN G H A M 8 .0 N o is e le v e l c h e c k N T A 3 0 1 4 /17 1 0 (1 /2 to 2/2 ) 5 7 to 5 8 J. N O T T IN G H A M 9 .0 L ig h t le v e l c h e c k N T A 3 0 1 4 /13 1 1 (1 /2 to 2/2 ) 5 9 to 6 0 J. N O T T IN G H A M 1 0 .0 M a n u a l p h a s e te s t N S C A 1 6 1 /2 5 N /A N /A J. N O T T IN G H A M 1 1 .0 E m e r g e n c y p h a s e te s t N S C A 1 6 1 /2 5 N /A N /A J. N O T T IN G H A M 1 2 .0 C le a n in g p h a s e te s t N S C A 1 6 1 /2 5 N /A N /A J. N O T T IN G H A M 1 3 .0 T e s tin g p h a s e t e s t N S C A 1 6 1 /2 5 N /A N /A J. N O T T IN G H A M 1 4 .0 P r o d u c tio n p h a s e te s t N S C A 1 6 1 /2 5 N /A N /A J. N O T T IN G H A M LA CALHENE IN S P E C T IO N S / T E S T S NAM E V erified b y P ##### © La Calhène 1997 D A T E & V IS A D a te & V isa CU STOM ER NAM E D A T E & V IS A CYCLE DEVELOPME DEVELOPMENT NT DEVELOPMENT PROGRAMME (1) (1) ETUDES & DEVELOPPEMENT VALIDATION 1 rue du Petit Clamart - B.P. 50 78142 VELIZY CEDEX - FRANCE Tél. 01.46.29.99.60 - Fax. 01.46.30.87.30 Doc N° : NSCA 161/37 C TEST GUIDE CD CONTROLS TESTS N° Page 8/30 Rev. Page B INSPECTION NOTES NSCA 161/38 N° Page TEST PROCEDURE 37 K 53 E MSD VALIDATION MANAGER LA CALHENE Nom Date & Visa 1.0 Prerequisites check N/A N/A N/A J. NOTTINGHAM 2.0 Isolators / VHP® generators OQ completion check N/A N/A N/A J. NOTTINGHAM 3.0 Check of IQ priority 1 punchlist for equipment completion N/A N/A N/A J. NOTTINGHAM 4.0 Isolator preparation N/A N/A N/A J. NOTTINGHAM 4.2. VHP inlet flow, uni-directional flow air speed and distribution fan flow checks NSCA 161/10, NTA 3014/9 1 (1/2 to 2/2) 3 to 4 J. NOTTINGHAM 4.3. Pre sterilization checks NTA 3022/1, NTA 3022/4, NTA 3022/6, NTA 3022/7 2 (1/1) 5 J. NOTTINGHAM N/A 3 (1/1) 6 J. NOTTINGHAM N/A 4 (5/14 to 6/14) 10 to 12 J. NOTTINGHAM NTA 3014/18 4 (1/14 to 14/14) 7 to 20 J. NOTTINGHAM 4.1. Initial positioning of temporary distribution fans 4.4. VHP programming and isolators sterilization recipe checks 5.0 Verification of data acquisition system and calibration of thermocouples 6.0 Temperature mapping and gaz distribution using chemical indicators LA CALHENE INSPECTIONS / TESTS Verified by P ##### MK 0826 Project : Reference LC : Client : © La Calhène 1997 NAME DATE & VISA CLIENT NAME DATE & VISA CYCLE DEVELOP DEVELOPMENT MENT NT DEVELOPME PROGRAMME (2) (2) ETUDES & DEVELOPPEMENT VALIDATION 1 rue du Petit Clamart - B.P. 50 78142 VELIZY CEDEX - FRANCE Tél. 01.46.29.99.60 - Fax. 01.46.30.87.30 Doc N° : NSCA 161/37 C TEST GUIDE CD CONTROLS TESTS N° Page 9/30 INSPECTION NOTES NSCA 161/38 N° Page TEST PROCEDURE 7.0 Base cycle verification and isolator reconfiguration 8.0 Verification of biological indicators 37 K 53 E MSD VALIDATION MANAGER LA CALHENE Nom Date & Visa N/A 5 (1/2 to 2/2) 21 to 22 J. NOTTINGHAM NTA 3022/6 6 (1/1) 23 J. NOTTINGHAM 9.0 Bio-decontamination capability using Bis NSCA 161/08 7 (1/24 to 24/24) 24 to 47 J. NOTTINGHAM 10.0 Aeration testing NSCA 161/08 8 (1/1) 48 J. NOTTINGHAM 11.0 Final cycle parameters N/A 9 (1/1) 49 J. NOTTINGHAM 12.0 Definition of final distribution fan positioning N/A N/A N/A J. NOTTINGHAM LA CALHENE INSPECTIONS / TESTS Verified by P ##### MK 0826 Project : Reference LC : Client : Rev. Page A © La Calhène 1997 NAME DATE & VISA CLIENT NAME DATE & VISA E XAMPLE OF A RECE RECENT NT EXAMPLE PROJECT (1) - Pre sterilisation checks Do’s - Prepare the isolator and the room, Limit access to test personnel only, Check that other project activities will not interfere, Hold daily progress meetings to keep all parties informed. P ##### © La Calhène 1997 Don’ts -Start with an element missing or faulty - compromises can bite back later on EXAMPLE OF A RECE RECENT NT PROJECT (2) -VHP generator qualification Calibration - do before starting cycle development tests Supply pipe work don ’t forget the risk of condensation Pressure reference point - don ’t forget possibility of pressure variations P ##### © La Calhène 1997 EXAMPLE OF A RECE RECENT NT PROJECT (3) - verification of data collection system and thermocouples Do’s -Calibrate thermocouples in advance, Make accurate and detailed records of the cable routings, Synchronise clocks on all test equipment, the VHP and isolator PLC P ##### © La Calhène 1997 Don’ts - Don ’ts forget to check that thermocouples will not catch in moving parts EXAMPLE OF A RECE RECENT NT PROJECT (4) - initial positioning of distribution fans Do’s - Define N° of fans during design Check for interference with other elements Check where supply cable will pass P ##### © La Calhène 1997 Don’ts - Forget to accurately record position in three dimensions before and after testing, EXAMPLE OF A RECE RECENT NT PROJECT (5) - Gas distribution studies Do’s -Prepare a « CI team ». It is best to have 3 people per team - 2 to read CIs and one to record the results, Train each member to recognise the same colour change, Split the isolator into sections, Use a gas concentration monitor (UOP). P ##### © La Calhène 1997 Don’ts - Don’t ask someone to read CIs unless they are perfectly familiar with each location looking for the CIs affects the results, Do not carry out test without a « map » for each tester EXAMPLE OF A RECE RECENT NT PROJECT (6) - BI tests Do’s - Work under controlled conditions and use « aseptic » techniques, Know the D value, Record any handling errors, Place BIs in « representative » areas only. P ##### © La Calhène 1997 Don’ts - Use too many locations, Use BIs without removing the packaging (some are supplied in paper/tyvek bags). NOTES STERILISATION NOTES ON STERILISATION CYCLE TESTING TESTING (1) GOOD GOOD PREPARATION AND GOOD CONTROL ARE OF UPMOST IMPORTANCE CYCLE CYCLE DEVELOPMENT FOR A SPECIAL PRODUCT SUCH AS A FILLING LINE SHOULD BE REGARDED AS A SEPERATE STAGE IN THE VALIDATION PROCESS POSITIONED BETWEEN OQ AND PQ P ##### © La Calhène 1997 E XAMPLE OF A RECE RECENT NT EXAMPLE PROJECT (7) - Sterility test suite PLC controlled transfer and workstation isolators VHP gas generator P ##### © La Calhène 1997 EXAMPLE OF A RECE RECENT NT PROJECT (8) - Sterility test suite qualification Operational Qualification ends with sterilisation tests using Bis 3 types of test: temperature mapping, CI tests and BI tests P ##### © La Calhène 1997 EXAMPLE OF A RECE RECENT NT PROJECT (9) - gas concentration transfer isolator using Polytron HC sensor Target concentration 1400 ppm P ##### © La Calhène 1997 EXAMPLE RECENT CENT EXAMPLE OF A RE NT RECE PROJECT (10) (10) - Technical support for PQ Sterilisation tests at end of OQ with islolator load P ##### © La Calhène 1997 A typical isolator load must be evenly distributed for good gas distribution E XAMPLE OF A RECE RECENT NT EXAMPLE RECENT PROJECT (11) - Technical support for PQ Advice on the use and positioning of environmental monitoring equipment P ##### © La Calhène 1997 Advice on isolator cleaning procedures and material compatibility Conclusion Isolator technology is one solution to perform aseptic processing The validation and the periodic re-validation is one important part to assure the profile of quality of the production The time dedicated to the validation and re-validation has to be taken in account for the production planning The reproducibility in the use of Isolation Technology brings an important safety factor when compared with manned Aseptic Processing Area P ##### © La Calhène 1997
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