Continuous Quality Verification: G.K.Raju, PH.D
Continuous Quality Verification: G.K.Raju, PH.D
VERIFICATION
(CQV)
G.K.Raju, Ph.D.
Research
Development
Manufacturing
Marketing
Pharmaceutical Manufacturing
Research
Inbound
Logistics
Bulk
Active
Development Manufacturing
Bulk
Formulation
Filling &
Finish
Marketing
Packaging
Outbound
Logistics
Plant A
Bulk
Formulation
Filling/
Tableting
Packaging/
Finishing
Plant B
Bulk
Active
HORIZONTAL
APPROACH
Bulk
Active
Bulk
Filling/
Formulation Tableting
Packaging/
Finishing
Bulk
Filling/
Formulation Tableting
Packaging/
Finishing
Plant B
Bulk
Formulation
Filling/
Tableting
Packaging/
Finishing
Bulk
Active
PHARMACEUTICAL MANUFACTURING
THE HORIZONTAL APPROACH
Company A
Bulk
Active
Bulk
Formulation
Filling/
Tableting/
etc.
Packaging/
Finishing
Bulk
Active
Bulk
Formulation
Filling/
Tableting/
etc.
Packaging/
Finishing
Bulk
Active
Bulk
Formulation
Filling/
Tableting/
etc.
Packaging/
Finishing
Company B
Company C
WHICH PROCESSES?
In Process
Development
In Routine
Manufacturing
DRY MIX
WEIGHING
QC1
API
MICRO
STEP
WET
GRANULATION
FB DRY
STEP
BLEND
SIEVE
QC2
QC3
ENCAPSULATE
QC4
WEIGH WETSTEP
GRANULN
7 DAYS
QC2
QC1
API
MICRO
LOD
SIEVE
ENCAPSULATE
QC3
Particle
Size
13 DAYS
QC4
Description
ID
Assay
CU
Impurity
Dissolution
MICRO
CHEMICAL
WEIGHING
QC1
API
OVI
BLEND
FILL CAPSULES
BOTTLE
PACKAGING
QC2
Description
ID
Assay
CU
Impurity
Dissolution
MIT PHARMACEUTICAL MANUFACTURING INITIATIVE (PHARMI)
CHEMICAL
WEIGHING
14 DAYS
BOTTLE
BLEND FILL
CAPSULES PACKAGING
7 DAYS
QC1
QC2
API
OVI
Description
ID
Assay
CU
Impurity
Dissolution
GRANULATION
WEIGHING
QC1
API
FB DRY
COMPRESS
STEP
FILM
BOTTLE
COATING PACKAGING
BLEND
QC2
Particle Size
LOD
QC2
Description
ID
Assay
CU
Impurity
Dissolution
6 DAYS
WEIGHING
QC1
API
FB DRY
STEP
COMPRESS
BLEND
BOTTLE
PACKAGING
FILM
COATING
14 DAYS
QC2
Description
ID
Assay
CU
Impurity
Dissolution
GRANULATION
CHEMICAL
WEIGHING
QC1
API
Processing
FILM
COATING
STEP
QC2
Particle Size
LOD
BOTTLE
PACKAGING
QC3
Description
ID
Assay
CU
Impurity
Dissolution
20 DAYS
15 DAYS
BLEND 2:
PRE-BLEND
FILM
COATING
GRANULATION STEP
CHEMICAL
WEIGHING
PROCESSING
BLEND 1:
FINAL
BLEND
COMPRESS
BOTTLE
PACKAGING
10 DAYS
QC1
API
15 DAYS
QC2
QC3
60 DAYS
MIT PHARMACEUTICAL MANUFACTURING INITIATIVE (PHARMI)
20 DAYS
15 DAYS
BLEND 2:
PRE-BLEND
FILM
COATING
GRANULATION
STEP
CHEMICAL
BLEND 1: FINAL COMPRESS BOTTLE
WEIGHING
PROCESSING
PACKAGING
BLEND
10 DAYS
QC1
21-90 DAYS
15 DAYS
QC2
QC3
60 DAYS
MIT PHARMACEUTICAL MANUFACTURING INITIATIVE (PHARMI)
Cycle Times
20
15
Actual
10
Target
Potential
5
0
QC1
PFD
QC3
20 DAYS
Release
15 DAYS
BLEND 2:
PRE-BLEND
FILM
COATING
GRANULATION STEP
CHEMICAL
WEIGHING
PROCESSING
BLEND 1:
FINAL
BLEND
COMPRESS
10 DAYS
QC1
BOTTLE
PACKAGING
15 DAYS
QC2
60 DAYS
QC3
Target
Potential
5
0
QC1
PFD
QC3
Release
2%
Sampling
Batching
Other Products
Waiting
Coordinating
TEST
Other Products
Other Paperwork
Waiting
Coordinating
WHICH PROCESSES?
In Process
Development
In Routine
Manufacturing
LOD
MILL
WEIGH
DRY MIX
WET
GRANULN
LOD
DRY
MIX
QC2 SIFT
BLEND
MIX
COATING STAGE
LOD
MILL
SIFT&BLEND STAGE
SIFT
MILL
COAT
MILL
WET GRAN
FL BED DRY
STORE
LOD
GRANUL
DRY
STORE
MIX
MIX
QC3
DRY
QC4
STORE
BLEND&FILL STAGE
BLEND
BLEND
BLEND
STORE
BOTTLE FILL
MILL
7 days
QC1
3 days
QC2
7 days
QC3
7 days
QC4
ACTIVE
<1 <1
day day
FIRST SECOND
GRAN GRAN
1-2 < 1
days day
COAT SIFT&
BLEND
<1
day
<1
day
BLEND
FILL
WHICH PROCESSES?
In Process
Development
In Routine
Manufacturing
WFI TESTING
Endotoxin
TOC
QC Check
WASH AUTOCLAVE
WFI
STOPPERS
WEIGH
QC Check
QC Check
WASH DEPYROGEN
BUFFER
SEALS
VIALS
WEIGH
ID
pH ADJ COMPOUND
WEIGH
ID
TERMINAL
FILL STOPPER CAP STERILIZATION
FILTER
pH
BIOBURDEN
LABEL/PKG
Wt Check
PROCESS F:
LIQUID LINE WITH CYCLE TIMES
ENVIRONMENTAL MONITORING
7 days
10 days
WFI TESTING
3-4 days
3-4 months
STERILITY TESTING
17-20 days
7 days
BIOBURDEN TESTING
Process
Flow
A
B
C
D
E
F
IN THE PROCESS/PLANT
IN QC/QA
Process/Unit operation
Interruption of the process
Securing of sample from process
Holding of sample in plant
Documentation and verification of sampling
Transferring of samples to QC lab
Batching of samples in QC
Preparation of test samples
Actual test - separation
Actual test - measurement
Test data collection and processing
Documentation and verification of testing
Transferring of results for review
Decision regarding impact on process
Process/Process Step
Inventory Hold
IN THE PROCESS/PLANT
IN QC/QA
Process/Unit operation
Interruption of the process
Securing of sample from process
Holding of sample in plant
Documentation and verification of sampling
Transferring of samples to QC lab
Batching of samples in QC
Preparation of test samples
Actual test - separation
Actual test - measurement
Test data collection and processing
Documentation and verification of testing
Transferring of results for review
Decision regarding impact on process
Process/Process Step
Inventory Hold
SUMMARY
Bulk
Formulation
Filling &
Finish
Packaging
Bulk
Active
Bulk
Formulation
Filling &
Finish
Packaging
Bulk
Active
Bulk
Formulation
Filling &
Finish
Packaging
Company B
Company C
Flow
Rapid
Fermentation Blending
Drying
Tableting Microbial
Granulation Transport Detection
MIT PHARMACEUTICAL MANUFACTURING INITIATIVE (PHARMI)
VERTICAL ANALYSIS I:
Bulk
Formulation
Filling &
Finish
Packaging
Bulk
Active
Bulk
Formulation
Filling &
Finish
Packaging
Bulk
Active
Bulk
Formulation
Filling &
Finish
Packaging
Company B
Company C
Eg. Blending
MIT PHARMACEUTICAL MANUFACTURING INITIATIVE (PHARMI)
WHICH PROCESSES?
In Process
Development
In Routine
Manufacturing
FOCUS
Explore the Potential Impact of On-line
Monitoring Technology on Blending
Process Development
Undermixed
mix-longer
Mixing
Active
Excipients
ingredient
Homogeneous
Blender
cleaning
Sampling
Next batch
Discarded
Next batch
Homogeneity test
OK?
Analysis
Transporting
PHARMACEUTICAL MANUFACTURING:
LIF FOR ON-LINE MONITORING OF BLENDING
4500
4000
3500
3000
2500
2000
1500
A: 5% T/L
1000
B: 5% T/L
500
C: 5% T/L
0
0
10
20
30
40
50
Number of Rotations
6
LIF % Triamterene A
LIF % Triamterene B
Thief Assay A
Thief Assay B
5
4
3
2
1
0
4.75%
3.22%
1.64%
Run Batch
PROCESS D:
BLENDING PROCESS DEVELOPMENT
CHEMICAL
WEIGHING
Processing
FILM
COATING
STEP
BOTTLE
PACKAGING
ON LINE SENSOR
GRANULATION
40
35
30
25
20
15
10
5
0
0
50
100
150
200
250
300
Number of Rotations
OFF LINE
Raw Materials
Process
knowledge
Blending
Sampling
Transport
Analysis
Results &
Decision making
Waiting Stock
Information Flow
R/D/W
Materials Flow
a- Process Development
ON LINE
Reprocessed
Raw Materials
Discarded
Well Blended
Blending
Analysis &
Decision making
b- manufacturing
Well Blended
Discarded
On-line
Information Feedback
MIT PHARMACEUTICAL MANUFACTURING INITIATIVE (PHARMI)
Operation Characteristics
Low
Medium
High
20
250
480
10
35
60
18
30
60
90
120
30
60
20
250
480
25
48
Results
Blending Performance
Process Development and Validation
6% no wait between blends
Time (days)
1 Blend
Best
2.32 0.36
Med.
13.19 1.31
Worst
25.82 2.57
2 Blends
4.96
3 Blends
0.68
8.45
1.07
23.45 1.93
30.65
2.41
43.40 3.56
56.17
4.46
Blending Performance
Process Development and Validation
Impact of the number of blends on total
process time
60
Time (days)
50
40
30.65
30
20
23.45
13.19
10
2.41
1.93
1.31
0
1
Number of blends
Avg Off line
Avg On line
MIT PHARMACEUTICAL MANUFACTURING INITIATIVE (PHARMI)
APPROACH TO LEARNING:
Consequences on Process Development & Commercial Production
Current Approach
Process Development
Proposed Approach
1a
2a
x
x
xxxxxxxxx
xxx
x
xx
xxxx
x
x xx xx
x x
x
x x x
x
Commercial Production
1b
x
x
xxxxxxxxx
xxx
x
2b
xxxxx
xxx
Hoffmann-La Roche
Aventis
Glaxo SmithKline
FDA
Vendors
CAMP
Purdue
MIT
MIT PHARMACEUTICAL MANUFACTURING INITIATIVE (PHARMI)
DRY MIX
WEIGHING
QC1
API
MICRO
STEP
WET
GRANULATION
FB DRY
STEP
BLEND
SIEVE
QC2
ENCAPSULATE
QC3
LOD
Particle Size
QC4
Description
ID
Assay
CU
Impurity
Dissolution
MICRO
Bulk
Active
t1
Y1
Bulk
Formulation
t2
Y2
Filling/
Tableting/
etc.
Y3
t3
Packaging/
Finishing
Y
Y4
t4
MATERIAL FLOW
MIT PHARMACEUTICAL MANUFACTURING INITIATIVE (PHARMI)
10.00
5.00
y = 1.9757x + 0.4886
0.0
2.0
4.0
6.0
8.0
10.0
10
5
0
0
R = 0.9983
0.00
30
25
20
15
50
100
150
200
250
Number of Rotations
300
Signals, volts
PMTSignal, volts
15.00
30
16
40
35
20.00
35
18
14
12
10
15
1%
0.5%
0.1%
4
1:10 powder flow
50
100
150
200
50
100
150
200
1:20
0
250
% of Triamterene
5%
20
10
12.0
10%
25
Signal, volts
25.00
Bulk
Active
Y1
Bulk
Formulation
Y2
Filling/
Tableting/
etc.
Y3
Packaging/
Finishing
Y
Y4
High Vol
Bulk
Active
Bulk
Formulation
Filling &
Finish
Packaging
Bulk
Active
Bulk
Formulation
Filling &
Finish
Packaging
Bulk
Active
Bulk
Formulation
Filling &
Finish
Packaging
Company B
Variable
Company C
Liquids
Flow
Rapid
Fermentation Blending
Drying
Tableting Microbial
Granulation Transport Detection
MIT PHARMACEUTICAL MANUFACTURING INITIATIVE (PHARMI)
CQV: BENEFITS
days
1000
100
10
0
50
100 150 200 250 300 350 400 450 500 550 600 650 700
batch #
CQV: SO WHAT?
On-line sensors doing the same thing will have
only incremental impact
This impact will still be only incremental
even if there is an MES/EBR system
Data Warehousing focused on exceptions can
have a large impact
On-line sensors + EBR + Data Warehousing
can fundamentally change pharma. mfg.
MIT PHARMACEUTICAL MANUFACTURING INITIATIVE (PHARMI)
2: NET INCOME
3: NET INCOME
370.88
2
1
Reduction of
manufacturing cost
3
Reduction of
time-to-market
1:
114.92
3
2
1:
-141.04
1.00
8.25
15.50
Years
22.75
30.00
Pharmaceutical Manufacturing:
Opportunity Areas
Manufacturing:
Cost --> Profit
Organizational focus: Functional --> Process
Optimization:
Local --> Supply chain
Inventory Management: JIC --> JIT
Cost of Quality: Inspection --> Prevention
ACKNOWLEDGEMENTS
NOTE ON CONTEXT