Getting Started (After the Equipment Specifications)
Process validation cannot begin when the first commercial size batch is produced. It must start much earlier. In reality, process validation begins in the basic research stage. While basic research itself is not under Good Manufacturing Practices (GMPs), the results that are obtained there are critical to successfully completing the PV process. There is a lot of information that needs to be collected and organized prior to starting an effective process validation program. There are four major categories of documents that are needed for any successful process validation project. These are:
• VMP
• Standard Operating Procedures (SOPs)
• Quality Programs (as standards)
• Protocols—(Commissioning, Equipment and Utility Qualifications, Process Performance Qualification)
Table 4.1 is a “wish list” of recommended documents and information that one should try to collect prior to starting the process validation. Many of these documents and drawings are critical to preparing the VMP. Others are needed for the protocols or SOPs. Be aware that each project is unique and not all documents are needed for every project. For example, the facility layout should also be available for the VMP so as to be able to show the paths that the materials and people will take in producing the product(s).
Table 4.1
Wish List
Reports
Development
Balance (eg, HVAC)
Cleaning
Passivation
Vendor tests—FAT/SAT
Weld
Drawings
PFD
P&ID
Vendor
Isometrics (WFI systems only)
Equipment layout
Air flow
People flow
Material flow
Material
In process
Raw materials
Waste material
Manuals
Cleaning
Operation
Preventive maintenance
SOPs
Backup
Calibration
Change control
Cleaning
Emergency
Sampling
Operation
Preventive maintenance
Training
Storage/warehousing
In process
Finished
Specifications
Engineering design
Functional requirement specifications (FRS)
Operating ranges
Critical process parameters
Critical quality Attributes
User requirements (URS)
Other Documents
Standards
Computer/systems
Ladder logic
Source code
Batch records
List of critical/noncritical instruments
Contractor certifications
Personnel qualifications
Equipment certifications
Logs
Equipment use
Cleaning
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