1. Good Manufacturing Practices Dar Es Salaam, Tanzania August 2006 Dr AJ van Zyl for Quality Assurance and Safety: Medicines Medicines Policy and Standards Health Technology and Pharmaceuticals Cluster World Health Organization

2. Program Good Manufacturing Practices Presentation on GMP (Production focus) Product specific focus Group session Presentation on GMP (QC focus) Product specific focus Group session

3. Guidelines and references GMP: World Health Organization WHO Technical Report Series, No. 908, 2003, Annex 4. Good Manufacturing Practices for pharmaceutical products: main principles WHO Technical Report Series, No. 917, Annex 3. Water WHO Technical Report Series, No. 937 HVAC and others (2006)

4. Good Manufacturing Practices (GMP) 1. Quality assurance 2. Good manufacturing practices for pharmaceutical products (GMP) 3. Sanitation and hygiene 4. Qualification and validation 5. Complaints 6. Product recalls 7. Contract production and analysis General The contract giver The contract accepter The contract

5. Good Manufacturing Practices (GMP) 8. Self-inspection and quality audits Items for self-inspection Self-inspection team Frequency of self-inspection Self-inspection report Follow-up action Quality audit Suppliers’ audits and approval 9. Personnel General Key personnel

6. Good Manufacturing Practices (GMP) 10. Training 11. Personal hygiene 12. Premises General Ancillary areas Storage areas Weighing areas Production areas Quality control areas

7. Good Manufacturing Practices (GMP) 13. Equipment 14. Materials General Starting materials Packaging materials Intermediate and bulk products Finished products Rejected, recovered, reprocessed and reworked materials Recalled products Returned goods Reagents and culture media Reference standards Waste materials Miscellaneous 15. Documentation General Documents required

8. Good Manufacturing Practices (GMP) 16. Good practices in production General Prevention of cross-contamination and bacterial contamination duringproduction Processing operations Packaging operations 17. Good practices in quality control Control of starting materials and intermediate, bulk and finished products Test requirements Batch record review Stability studies

9. Good Manufacturing Practices (GMP) Production Utilities Equipment Dosage form and data verification (development, validation, biobatch, stability, BMR and specification) Quality control API, excipients Packaging material Data verification (e.g. stability)

10. Good Manufacturing Practices (GMP) Production Product focus Premises Utilities Equipment Dosage form and data verification (development, validation, biobatch, stability, BMR and specification) Documentation

11. Good Manufacturing Practices (GMP) Where to start the inspection? Facility layout Flow of personnel and material, activities Product list Type of products, dosage forms, activities Utilities (HVAC, water, etc) Validation status

12. Zone: Clean Zone: Packaging Zone: Controlled Example of Materials and People Flow

13. Facility layout Flow of personnel and material, activities Sampling (starting materials and packaging materials) Weighing Mixing Milling Sieving/sifting/screening Granulation Drying Sieving Blending Compression

14. Facility layout Flow of personnel and material, activities In process bulk stores Packaging areas (primary and secondary packaging) Finished product

15. Product list Type of products, dosage forms, activities Multi-product Various tablets Uncoated artesunate Risk of cross-contamination and contamination Non dedicated areas and equipment Batch to batch consistency

16. Facility layout Flow of personnel and material, activities Batch Manufacturing Document Formula and manufacturing steps API and excipients Properties and requirements for temperature or RH control Material quantities, batch size Sub lots Equipment and utilities Production areas

17. Equipment and utilities (1) Sieving/sifting – sifter (e.g. vibrosifter) Mixing – mixer Granulation - granulator Drying – fluid bed drier Blending – octagonal blender Compression – compression machine Packaging - blister machine Others include Metal detector, sieves, punches and dies In process quality control instruments and equipment may include hardness tester, disintegration tester, balance, caliper

18. Equipment and utilities (2) HVAC – air supply and extraction Compressed air – machine operation, drying of equipment and parts Water – washing, rinsing, manufacture Steam – cleaning

19. Utilities The environment may be influenced by: Light Temperature Humidity Air movement Microbial contamination Particulate contamination Uncontrolled environments can lead to: Product degradation Product contamination Loss of Product & Profit

20. Utilities HVAC : GMP and GEP Effective ventilation Cross-contamination and contamination Qualification/validation Design Installation Operation Performance

21. Red: Supply Green: Exhaust Air supply and extraction

22. Problems with components Filters Filters Fan Fan Flow rate controller Flow rate controller Control damper Control damper Humidifier Humidifier Cooling coil Cooling coil Ducts Ducts Incorrect retention rate/leaking/badly installed Low air flow ® loss of pressure cascade Blocked ® poor pressure cascade ® cross- contamination Poorly adjusted, bad pressure differential system Bad water/steam quality/poor drainage/ No elimination of condensed water/poor drainage/stagnating water Inappropriate material/internal insulation Leaking ducts

23. Utilities: Water systems Type of water Intended use Quality (specification) Design of the system Qualification and validation Ongoing monitoring and quality control Sampling, testing, trends

24. Validation status Validation Master Plan Manufacturing areas Utilities Equipment Manufacturing process Cleaning validation Computer systems Others…

25. On site verification From receiving to stores Sampling and weighing Manufacturing areas Utilities Documentation review

26. Sampling and weighing

27. Examples of control measures: Temperature Cooling coil Relative humidity Dehumidifier Particulate matter Filters Air movement and pressure differentials Fan

28. Re-circulation Air System ISPE Baseline Vol. 2 #6.3.3 (d) WHO HVAC Guideline HEPA filters installed?

29. Cationic column Anionic column Hygienic pump Outlets or storage. Ozone generator UV light HClNaOH Eluates to neutralization plant Air break to sewer Drain line from water softener Water must be kept circulating Typical de-ionizer schematic 1 2 3 4 5 6 1 2 3 4 5 6 Return to de-ioniser Cartridge filter 5 µm Cartridge filter 1 µm

30. Documentation review HVAC DQ, IQ, OQ, PQ Important aspects including air flow direction, filtration, air changes, pressure differentials Water DQ, IQ, OQ, PQ Sampling and testing

31. Documentation review Equipment and utilities SOPs (operation, cleaning, calibration) Records and use logs Calibration records/certificates Preventative maintenance and maintenance Qualification

32. Documentation review Product related Batch Manufacturing document as per product dossier Process Validation protocol and report Bio-batch records Stability batches Batch records

33. Documentation review Other documents SOPs including: Cleaning Complaints Recalls Validation protocols and reports including: Cleaning validation Computer validation

34. Documentation review Inspection of the quality control laboratory…

35. Group session Group 1 Group 2