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    51st Land O'Lakes J une 20

    Technology Transfer

    Technology TransferTechnology Transfer

    Edmund J. Elder, Jr., Ph.D., R.Ph.Director

    eje | June 2009 51st Land O'Lakes 0

    Lenor Zeeh Pharmaceutical Experiment Station

    Technology TransferTechnology Transfer

    Office of CorporateRelations

    University ResearchPark

    WARF (Wisconsin AlumniResearch Foundation)

    eje | June 2009 51st Land O'Lakes 1

    Transferring the results of University applied

    and direct research to solve real-worldproblems

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    Technology Transfer

    OutlineOutline

    Introduction to Technology Transfer

    Facilities

    Equipment

    Scale-up

    (pre-) Validation

    eje | June 2009 51st Land O'Lakes 2

    ec no ogy rans er u ance

    Who is responsible for technology transfer?

    When does it occur during development?

    DefinitionsDefinitions

    Technology Transfer Drug Substance manufacturing process

    transfer

    Analytical method transfer

    Drug Product manufacturing process transfer

    Scale-up Increase in batch size from development scale

    to ilot scale to full scale manufacturin

    eje | June 2009 51st Land O'Lakes 3

    Validation Documented evidence that a system is

    designed to assure that the processconsistently performs as it purports to do.

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    Technology Transfer

    Technology TransferTechnology Transfer

    The ultimate test of scientific reproducibility:

    The successful transfer of production responsibilities

    from development scientists to production personnel

    eje | June 2009 51st Land O'Lakes 4

    When does Tech Transfer occur?When does Tech Transfer occur?

    Depending on organization, frequently!

    re ormu a on

    Pre-clinical Formulation

    Phase 1/2a Formulation

    Phase 2b/3 Formulation

    Development

    eje | June 2009 51st Land O'Lakes 5

    Production Support

    Manufacturing/Validation/QC

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    Technology Transfer

    What Technologies are Transferred?What Technologies are Transferred?

    Development

    Chemical Development

    Manufacturing

    Drug Substance

    Active PharmaceuticalIngredient (API)

    Analytical Development& Clinical QA

    Methods &Specifications

    Manu acturing Site

    Active PharmaceuticalIngredient (API)

    QA / QC

    Methods &Specifications

    eje | June 2009 51st Land O'Lakes 6

    ro uct eve opment

    Dosage Form

    Development Manufacturing Process

    Development

    rug ro uctManufacturing Site

    Manufacturing ProcessValidation

    Successful Tech TransferSuccessful Tech Transfer

    Process must be well defined Identify areas of criticality, sensitivity

    and/or weakness Analyze operational boundaries, risks

    Must be robust in R&D if expected inProduction/QC

    Minimize process improvements

    eje | June 2009 51st Land O'Lakes 7

    .e. c angesMembers of Development andProduction work jointly during initialrun(s)/campaign

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    Technology Transfer

    21 CFR Subpart F21 CFR Subpart F 211.100(a)211.100(a)

    to assure

    Identity

    Strength

    Quality Functionality

    eje | June 2009 51st Land O'Lakes 8

    ur y

    of drug product.

    What are the challenges?What are the challenges? Technological

    Facilities

    E ui ment

    Unit operations/processes

    Overall process train no two are the same!

    Personnel Communication across organization

    Remote sites

    eje | June 2009 51st Land O'Lakes 9

    ,

    R&D = Creative, responsible for inventing change

    Process Development = Problem solvers, troubleshooters

    Production/QC = Detail-oriented, disciplined, observant Quality by Design demands innovation throughout!

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    Technology Transfer

    Linking Material AttributesLinking Material Attributes

    Excipient Functionality ProposedUSP General Chapter

    Excipient Performance Pharmacopeial Forum 33(4), 2007

    PhEur General Chapter Functionality Related Characteristics (FRCs) of Excipients (5.15)

    Draft: Pharmeuropa 18(3), 2006 Adopted: Council of Europe, Supplement 6.1, Chapter 5.14, PhEur (2007)

    EMEA Committee for Medicinal Products for Human Use,Guideline on Excipients in the Dossier for Application forMarketing of Medicinal Product, November 2006

    ICH Q8, Guideline on Pharmaceutical Development,

    eje | June 2009 51st Land O'Lakes 10

    ovem er Quality by Design [QbD][QbD]

    DHHS-FDA, Pharmaceutical cGMPs for the 21st

    Century ARisk-Based Approach, September 2004

    OutlineOutline

    Introduction to Technology Transfer

    Facilities

    Equipment

    Scale-up

    re- Validation

    eje | June 2009 51st Land O'Lakes 11

    Technology Transfer Guidance

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    Technology Transfer

    Manufacturing Site ConsiderationsManufacturing Site Considerations

    Facility Design

    Management

    Training

    Experience

    Documentation

    eje | June 2009 51st Land O'Lakes 12

    n erac ve e a ons p

    Parent : Child

    Siblings

    Peers

    Facility DifferencesFacility Differences

    ~23

    eje | June 2009 51st Land O'Lakes 13

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    Technology Transfer

    Equipment DifferencesEquipment Differences

    Blenders / Granulators Rate of Shear Geometry Size

    Tablet Presses Compression Mechanism - mechanical,

    pneumatic Units of Force

    eje | June 2009 51st Land O'Lakes 14

    Coating Pans

    Size Air handling system

    CapsulesCapsules

    Pi lo t Sca le / Mfg S ite 1 Ful l Scale / Mfg Si te 2

    20

    40

    60

    80

    100

    rcentDissolved

    eje | June 2009 51st Land O'Lakes 15

    -20

    0

    0 5 10 15 20 25 30 35 40 45 50

    Time (min)

    Pe

    Elder, et. al. , Glaxo Research Institute, AAPS 1993 SERM

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    Technology Transfer

    Domestic vs. InternationalDomestic vs. InternationalManufacturing ConsiderationsManufacturing Considerations

    RegulatoryRe uirements

    ExcipientS ecifications

    NDA

    MAA

    JNDA

    NDS (Canada)

    USP/NF

    BP

    Ph.Eur.

    JP

    FCC

    eje | June 2009 51st Land O'Lakes 16

    < ICH >

    CTD

    GRAS

    WHO FDA Inactive

    Ingredients Guide

    Target Product ProfileTarget Product Profile Target disease Target patient population Tar et indication s

    Specific level of desired and minimal acceptable safety Specific level of desired and minimal acceptable efficacy Specific level of desired and minimal acceptable tolerability

    Target route of administration Target dose and dosing regimen and acceptable range of

    deviation Course/duration of treatment

    Target drug product presentation and acceptable range of

    eje | June 2009 51st Land O'Lakes 17

    deviation Packaging, Storage conditions, shelf life, etc.

    Target markets & market size Target cost and acceptable overage Target price and acceptable range

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    Technology Transfer

    Market ImageMarket Image

    Product Identification

    worldwide regulatory requirements

    Colorants

    Worldwide Acceptability

    Titanium Dioxide (White)

    eje | June 2009 51st Land O'Lakes 18

    Iron Oxide Red

    Iron Oxide Yellow FD&C Blue #2

    Effective Process scaleEffective Process scale--upup

    Approach lab process as scaled-down

    Understand the unit processes

    Spray-drying: effect of nozzle,atomization P, flow rate on droplet size,spray pattern, velocity

    eje | June 2009 51st Land O'Lakes 19

    Sterile product: mode of sterilization,

    filtration, stirring rate, shear rate, batchsize

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    Technology Transfer

    What lends to process scalability?What lends to process scalability?

    No change between type of equipment

    No significant change betweensurface-to-volume ratio

    Unit process is scaled up byrepetition, not by increase in volume

    eje | June 2009 51st Land O'Lakes 20

    Process less sensitive to time,temperature

    Additional ScaleAdditional Scale--up considerationsup considerations

    especially for Biologicals

    -

    Specs for process control, operator interface

    Contractors and the Request for Proposal process

    Integrating automation

    Installation, Commissioning, Development, FAT

    Equipment, Process, Cleaning Validation

    eje | June 2009 51st Land O'Lakes 21

    Maintenance= long lead times!!!

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    Technology Transfer

    drug excipients drug excipients

    Scaling up a suspension formulationScaling up a suspension formulation

    Batch size Biobatch

    10 liters

    Commercial

    batch 100 liters

    eje | June 2009 51st Land O'Lakes 22

    Mixing time 15 mins 45 mins

    Adapted from Colin R. Gardner, Presentation to Manufacturing Subcommittee of the FDA Advisory

    Committee for Pharmaceutical Science, Sept 17, 2003

    Are these processes equivalent?

    Components of ValidationComponents of Validation

    Qualification

    IQ

    OQ

    PQ

    RQ

    Installation

    Operational

    Process

    Re-

    eje | June 2009 51st Land O'Lakes 23

    Change Control

    Pre-Validation QbD considerations

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    Technology Transfer

    Upper Level of Failure

    Process RangesProcess Ranges

    Upper Proven Acceptable Level

    Upper Control Level

    Upper Operating LevelControl Range

    TARGET Operating Range

    Lower Operating Level Batch Record Limits

    eje | June 2009 51st Land O'Lakes 24

    Lower Proven Acceptable Level Regulatory Limits

    Lower Level of Failure

    Lessons LearnedLessons Learned Build quality systems early,

    evolve strategically

    Define commercial productearly

    for a fast-growingworkforce; hire, trainahead of curve wherepossible

    Understand the chemistryof the system

    Understand the

    will work the first time!

    Beware the law ofunintended consequences

    Put change controlprocedures in place early

    Scale-UP communication

    Work with FDA, not against

    eje | June 2009 51st Land O'Lakes 25

    the process

    Take advantage of outsideexpertise

    t em Track the dynamically

    changing regulatorypicture!

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    Technology Transfer

    CQACQA

    If you fail to pull asample at any (non-)

    Softgel Process Steps API

    process

    That will be thesample that couldhave identified thecause of our roblem.

    xc p en s

    Mixing

    Milling

    Filling

    Drying

    Sizing

    Printing

    eje | June 2009 51st Land O'Lakes 26

    Inspection

    Polishing

    Packaging Shipping / Distribution

    OutlineOutline

    Introduction to Technology Transfer

    Facilities

    Equipment

    Scale-up

    re- Validation

    eje | June 2009 51st Land O'Lakes 27

    Technology Transfer Guidance

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    Technology Transfer

    Technology Transfer GuidelineTechnology Transfer Guideline

    Standardized Process

    Analytical Methods

    Active Pharmaceutical Ingredients (APIs)

    Dosage Forms

    eje | June 2009 51st Land O'Lakes 28

    ISPE Good Practice Guide, Technology Transfer, 2003

    ObjectivesObjectives

    To describe information that needs to...

    to support manufacture

    to provide for regulatory filings

    To provide effective approaches forensuring information is available at

    eje | June 2009 51st Land O'Lakes 29

    the point of use.

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    Technology Transfer

    Quality of Pharmaceutical ProductsQuality of Pharmaceutical Products

    Robust manufacturing processes

    in accordance with cGMPs

    facilitate ease of validation

    Extensive information set defines all activities necessary to:

    eje | June 2009 51st Land O'Lakes 30

    control

    measure

    relevant and up-to-date

    Definition of SuccessDefinition of Success

    Receiving unit can routinely reproduce

    roduct

    process

    method

    against a predefined set of specifications

    as agreed with the sending and/or development unit

    eje | June 2009 51st Land O'Lakes 31

    e u a e nv ronmen Documentation is CRITICAL

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    Technology Transfer

    Experience & Knowledge CaptureExperience & Knowledge Capture

    R&D to Manufacturing

    formulation and rational

    Site to Site

    manufacturing process

    pivotal batch data

    processevolution/history

    Business Factors

    cost

    an rationa

    annual product reviewdocumentation

    batch comparison data

    pivotal batch data

    clinical, bio,stability,registration

    eje | June 2009 51st Land O'Lakes 32

    facilities and equipment

    timelines regulatory requirements

    batch list and pedigree

    size, use, etc.

    Dosage FormDosage Form

    API

    Manufacturing Process

    Manufacturing Facility & Equipment

    Packaging/Device Components

    eje | June 2009 51st Land O'Lakes 33

    ac ag ng pera onsHealth, Safety & Environmental

    Qualification and Validation

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    Technology Transfer

    General Excipient InformationGeneral Excipient Information

    Functionality

    Manufacturer

    RegulatoryConsiderations

    Specifications

    Special Considerations

    heat, light, moisture,etc.

    HS&E

    Compendial Status

    Grade

    Validation/Qualificationof multiple suppliers

    Drug Master File

    Residual Solvents /

    eje | June 2009 51st Land O'Lakes 34

    Impurities

    BSE / TSE Allowable range of use

    SUPAC

    Excipient CharacterizationExcipient CharacterizationCharacteristic Oral Solid Parenteral

    Semisolid/

    Topical Liquid Transdermal Inhalation

    Form/ Morphology X X

    PS/ PSD X X X

    Bulk Density X X

    Compaction X

    Solubility X X X

    Water Content/

    Hygroscopicity/

    Moisture Content

    X X X X X X

    pH/ Ionic Strength X X X X

    Specific Gravity/

    DensityX X X X

    Viscosity X X X X

    Osmolarity X

    eje | June 2009 51st Land O'Lakes 35

    cro o ogca

    Considerations X X X X X

    Melting Range X

    Partition

    CoefficientX

    Intrinsic

    DissolutionX

    Adhesive

    PropertiesX

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    Technology Transfer

    Experience & Knowledge CaptureExperience & Knowledge Capture

    Critical processing parameters

    critical analytical data (release and stability)

    Qualitative and quantitative compositions

    known differences in suppliers andperformance

    eje | June 2009 51st Land O'Lakes 36

    equipment

    Comparison of analytical methods andinstrumentation

    More DetailsMore Details

    See Extra Slides

    eje | June 2009 51st Land O'Lakes 37

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    Technology Transfer

    Technology Transfer TeamTechnology Transfer Team

    Core Expertise Product Development

    Manufacturing ormu a on

    Development

    Process Development

    Analytical

    Device Development

    Packaging Development

    ro uc on Manufacturing

    Packaging

    Technical Support

    Engineering

    QualityAssurance/Control

    Validation

    eje | June 2009 51st Land O'Lakes 38

    Supporting Expertise

    Regulatory Health/Safety/

    Environmental

    Line Management

    Support

    Keys to Successful Product TransferKeys to Successful Product Transfer

    Establish trust between development,transfer and manufacturing groups

    ree n orma on exc ange Communication Open mind to diversity and alternate

    ideas/options Develop a standardized transfer policy

    Define teams

    eje | June 2009 51st Land O'Lakes 39

    Establish information requirements Identify activities and responsibilities

    Identify manufacturing site(s) early indevelopment

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    Technology Transfer

    Technology Transfer ProcessTechnology Transfer Process

    R & D

    TechnologyTechnology

    TransferTransfer

    GroupGroup

    Environment

    Large Scale

    ManufacturingPersonnel

    Small Scale

    ResearchPersonnel

    Less

    eje | June 2009 51st Land O'Lakes 40

    Resourceconstrained

    Routine Mode

    constraints

    ExperimentalMode

    Scale Up and Technology TransferScale Up and Technology Transfer

    Technology transfer and scale-up ofpharmaceutical dosage forms must be wellcontrolled and scientificall based Transfer interactions, activities, and documentation must

    be well defined. Pilot facilities must be constructed and equipped to

    adequately simulate full scale manufacturing operations. Formulation and components must be well characterized

    early in development. The manufacturing process must be well characterized

    and critical process variables must be identified,

    eje | June 2009 51st Land O'Lakes 41

    mon tore an contro e ur ng sca e-up. The ultimate goal of all scale-up and transfer

    activities is to produce a product meeting allquality standards on a routine basis in production.

    Adapted from: R.M.Franz, Glaxo, ~1992

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    Technology Transfer

    www.pharmacy.wisc.edu/zstationwww.pharmacy.wisc.edu/zstation

    [email protected]

    eje | June 2009 51st Land O'Lakes 42

    EXTRA SLIDESEXTRA SLIDES

    Technology Transfer

    eje | June 2009 51st Land O'Lakes 43

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    Technology Transfer

    Chemical Development RoleChemical Development Role

    Develop synthetic route & scheme for efficiency,reliability, scalability

    Outline Batch Manufacturing Records Identify in-process variables Recommend in-process specifications Identify critical process variables for validation Assist with conducting and documenting

    validation

    eje | June 2009 51st Land O'Lakes 44

    Prepare technology transfer report Oversight of initial runs in production Assist with troubleshooting production problems Key chemistry/chemical engineering contact

    Product Development RoleProduct Development Role Develop drug product manufacturing process for

    efficiency, reliability, scalability

    Outline Batch Manufacturing Records Identify in-process variables Recommend in-process specifications Identify critical process variables for validation Assist with conducting and documenting

    validation

    eje | June 2009 51st Land O'Lakes 45

    Prepare technology transfer report Oversight of initial runs in production Assist with troubleshooting production problems Key scientific contact for formulation/process

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    Technology Transfer

    Analytical Technical TransferAnalytical Technical Transfer RoleRole

    Has led or contributed to developing analyticalmethods for efficienc , reliabilit , scalabilit

    Has managed or assisted initial methods transferto QC

    Assists in preparing Analytical Test Procedures

    Trains QC staff

    Establishes RM and product specs

    Pre ares Tech Transfer rotocol and re ort

    eje | June 2009 51st Land O'Lakes 46

    Prepares and/or reviews Validation protocols

    Directs Methods Transfer Validation Troubleshoots QC problems

    Key scientific/QC chemist contact

    RoadblocksRoadblocks

    R&D prima donna syndrome Manufacturing fire fighting Lack of organizational teamwork Band-aid fixes Lack of product focus

    Analytical Packaging

    eje | June 2009 51st Land O'Lakes 47

    Dissolution

    Acceptance criteria and responsibility notwell defined - commercial vs. developmentbatches

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    Technology Transfer

    EXTRA SLIDESEXTRA SLIDES

    Technology Transfer Guidance

    eje | June 2009 51st Land O'Lakes 48

    Regulatory FactorsRegulatory Factors

    Pre-defined specification

    Establishment of protocols andStandard Operating Procedures(SOPs)

    eje | June 2009 51st Land O'Lakes 49

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    Technology Transfer

    Analytical Methods TransferAnalytical Methods Transfer

    Tests API Dosage FormSemi-solids/

    Ointments/ Liquids/

    Solids Parenterals Inhalation Creams Suspensions Transdermals Ophthalmic

    Assay X X X X X X X X

    Content

    UniformityX X X X X X X

    Impurities/

    DegradantsX X X X X X X X

    Dissolution/

    Release Rate/

    Dose Delivery

    X X X X

    Identification X X X X X X X X

    eje | June 2009 51st Land O'Lakes 50

    Cleaning

    VerificationX X X X X X X X

    MicrobiologicalX X X X X X X X

    Physical Criteria X X

    APIAPIActive Pharmaceutical IngredientActive Pharmaceutical Ingredient

    Synthetic Route

    Form

    Process Critical Parameters

    Process Materials Starting Materials

    Raw Materials

    Reagents

    Catalysts

    In-process Controls

    Characterization API & Intermediates

    Cleaning

    Reprocessing

    eje | June 2009 51st Land O'Lakes 51

    ac tyEquipment

    Health, Safety &Environmental

    Qualification &Validation

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    Technology Transfer

    BACPACBACPACBulk Active postBulk Active post--Approval ChangesApproval Changes

    I - Intermediates

    II - Drug Substance

    Types of change

    Manufacturing site,

    (to be issued)

    Assessment of effectsof change

    Equivalence of impurityprofiles

    sca e, or equipment

    Specifications

    Manufacturing process

    Multiple changes

    Regulatory Filings

    eje | June 2009 51st Land O'Lakes 52

    qu va ence o p ys caproperties

    Supplement

    Changes Being EffectedSupplement

    Annual Report

    API Information RequirementsAPI Information Requirements

    Manufacturer

    Flow Chart of

    MicrobiologicalConsiderations

    Synthetic Pathway

    Form / Morphology

    Solubility

    Partition Coefficient

    Intrinsic Dissolution

    Specifications

    Stability

    Synthetic Impurities

    Degradants

    Potency Factor

    eje | June 2009 51st Land O'Lakes 53

    PS PSD Bulk & Tap Density

    Water Content /Hygroscopicity

    Specia Consi erations heat, light, moisture,

    etc.

    HS&E

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    Technology Transfer

    Microbiological ConsiderationsMicrobiological Considerations

    Microbial Limit Tests

    Sterility Tests

    Bacterial Endotoxins Test

    Pyrogen Test

    Particulate Matter in Injections

    Microbiological Attributes of NonsterilePharmaceutical Products

    Sterilization and Sterility Assurance of

    eje | June 2009 51st Land O'Lakes 54

    Compendial Articles

    Validation of Microbial Recovery fromPharmaceutical Articles

    Water for Pharmaceutical Purposes

    Excipient JustificationsExcipient Justifications

    Preservative Level

    Antimicrobial Effectiveness Testing

    Antimicrobial Agents - Content

    Antioxidants

    no compendial tests, but similar expectation

    Concentrations above guidelines

    FCC limits

    eje | June 2009 51st Land O'Lakes 55

    WHO limits

    FDA Inactive Ingredients Guide Excipient Biological Safety Evaluation Guidelines

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    Technology Transfer

    SUPACSUPACScaleScale--up and postup and post--Approval ChangesApproval Changes

    IR

    immediate release

    Regulatory Filings

    Prior Approval

    MR

    modified release

    SS

    non-sterile semisolids

    PACSAS

    sterile a ueous solutions

    Supp ement

    Changes Being EffectedSupplement

    Annual Report

    eje | June 2009 51st Land O'Lakes 56

    PAC-ATLS

    analytical testing labsites

    SUPACSUPAC--IRIR

    Types of Change

    Level I

    Change I II III

    Components AR PAS PAS+BE

    unlikely to have anydetectable impact...

    Level II

    could have significantimpact...

    Level III

    mnor non-cr cr

    1 stab 3 accel 3 accel

    Site AR CBE CBE

    same different different

    (+) data (-) data

    1 stab 3 accel

    Batch Size AR CBE

    10x pilot

    1 stab 1-3 accel

    eje | June 2009 51st Land O'Lakes 57

    likely to havesignificant impact...

    on formulationquality andperformance

    Equipment AR CBEsim oper different

    1 stab 1-3 accel

    Process AR CBE PAS

    >val< val different

    1 stab 1-3 accel

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    Technology Transfer

    EXTRA SLIDESEXTRA SLIDES

    Acceptance Criteria

    eje | June 2009 51st Land O'Lakes 58

    Quality Acceptance CriteriaQuality Acceptance Criteria

    Manufacture of Validation Batches Process and Controls Conform to Registration

    Dossier

    Process Meets Acceptance Criteria

    Product Meets Regulatory Specifications

    Commercial Product Equivalence Pilot Scale

    eje | June 2009 51st Land O'Lakes 59

    Bioequivalence Batch(es)

    cGMP Compliance

    Transfers often stop hereTransfers often stop here

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    Technology Transfer

    Manufacturing Acceptance CriteriaManufacturing Acceptance Criteria

    Manufacturing Cycle

    Throughput

    Manufacturing Process

    Ranges for Processing

    Time - Single Shift?

    Cleaning

    Water / Detergents /Solvents ?

    Downtime ?

    Equipment Effectiveness

    Availability

    Parameters

    Process Yield

    Minimize Material Waste

    Process Capability Index

    Six Sigma Excellence

    eje | June 2009 51st Land O'Lakes 60

    Efficiency

    Defect Rate

    Cost

    Packaging & Labeling multiple configurations

    and languages

    Influence MatrixInfluence Matrix

    sStep

    ses

    rge

    Charac

    teris

    tics

    ation

    Qua

    lity

    Loa

    d

    reCon

    ten

    t

    Size

    Distribu

    tion

    ropert

    ies

    ity

    ight

    Varia

    tion

    tUn

    iform

    ity

    tion

    Proces

    Respo

    Disc

    ha

    Granu

    l

    Power

    Mo

    istu

    Part

    icl

    Dens

    it

    Flow

    P

    Dens

    it

    Un

    ifor

    FillWe

    We

    ight

    Con

    ten

    Disso

    l

    Process Variables G G G D S S B B B F F P PG Batch Size S S S ? ? ? N ? ? ? ? ? N

    G Speed - main W M S N W W N N N N N N N Notes:

    G Speed - chopper M W W N W W N W N N N W W S Strong Effect

    G Amount of Water S S M S S S S S W S S W S M Moderate Effect

    G W ater Addition Rate W S W N W W W W M W N N N W Weak Effect

    G Graulating Time S S N N M M M M W M M S S N No Effect

    D Initial Temperature X X X N M N M W N W N N N ? Unknown E ffect

    D Drying Temperature X X X S W M M N N N N N N X Not Applicable

    D Air Flow Program X X X S W M N N N N N N N

    D Drying Time X X X S W M M N M M N N M

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    S Screen Size X X X X S M W W N N N N W Process Steps:

    S Feed Rate X X X X M W N N N N N N N G Granulating

    B Loading X X X X X X N N W N N W N D Drying

    B Speed X X X X X X N N W N N N N S Sizing

    B Blending Time X X X X X X N N S N N S N B Blending

    F Powder Level X X X X X X X X X S S N N F Filling

    F Tamper Settings X X X X X X X X X S S N W P Product

    F P owder Dispersion Aid X X X X X X X X X M M N N

    von Doehren et. al., Pharm Tech, 6(9):1982, 145

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    Confidence IntervalsConfidence Intervals

    t0.05 x Standard Deviation95% C.I. = mean +/-

    n 1/2

    t0.05 x Standard Deviation95% C.I.ind = mean +/-

    ( n + 1 ) 1/2

    Population parameter with stated confidence Data will be within stated limits 95% of the time

    eje | June 2009 51st Land O'Lakes 62

    Useful for establishing batch record or validation limits

    Tolerance IntervalsTolerance IntervalsT.I.p = mean +/- ( kp, x Standard Deviation )

    Confidence statement for a coverage of population

    Interval containing p% of the population - 2 sided

    p% will not exceed lower (upper) limit - 1 sided

    Wider than Confidence Intervals

    Useful for predicting the distribution of data within a batch

    eje | June 2009 51st Land O'Lakes 63

    Can be used to guide establishment of regulatory limits

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    Process Capability IndexProcess Capability Index

    Mean - Lower Limit Upper Limit - Mean

    pk = min ,3 x Standard Deviation 3 x Standard Deviation

    < 1.0 Process is Not Capable

    1.0 - 1.33 Process is Marginal

    eje | June 2009 51st Land O'Lakes 64

    . - .

    > 3.0 Process is Excellent

    Miller & Miller, Statistical Methods for Quality with Applications to Engineering and Materials, Prentice-Hall, pp.214-

    218, 1995.

    Process Capability and Process FailureProcess Capability and Process Failure

    Batch Failures er Million

    100

    10000

    1000000

    Num

    ber

    eje | June 2009 51st Land O'Lakes 65

    0.4 0.6 0.8 1 1.2 1.4 1.6

    Cpk

    A.J.Duncan, Quality Control and Industrial Statistics, Irwin, p.456, 1986.

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    Process Capability for Technology TransferProcess Capability for Technology Transfer

    1.4

    1.6

    1.8

    2

    2.2

    2.4

    Cpk

    1.25

    1.5

    1.75

    >2.0

    eje | June 2009 51st Land O'Lakes 66

    1

    1.2

    Development Scale-up Optimization Production

    Process Stage

    Cautions for Using CCautions for Using Cpkpk

    Statistical control should be achieved before using Cpk Data must approximate a normal distribution

    Can un erestimate e ects i not enoug ata are avai a e

    Non-representative sampling may result in high estimatesof Cpk

    Treats both ends of the specification equally

    Only a good as the specifications on which it is based

    Not a summary parameter (can not be averaged)

    eje | June 2009 51st Land O'Lakes 67

    Focus on reducing variability rather than Cpk Could result in wider specifications than necessary

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    Six SigmaSix Sigma

    Business philosophy eliminate defects through fundamental process

    Business, statistical and engineering tools reduce costs through self-funded improvement reduce waste better understand customer requirements improve delivery and quality performance

    eje | June 2009 51st Land O'Lakes 68

    changing customer requirements

    develop robust processes and products drive rapid improvement

    Six Sigma PerformanceSix Sigma Performance

    99.9997%

    Why 99% is not goodenough

    30 spelling mistakes perpage

    20,000 letters lost daily

    15 minutes of electricalfailure per day

    eje | June 2009 51st Land O'Lakes 69

    each major airportglobally

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    Lean ManufacturingLean Manufacturing

    Tools to reduce waste and streamline

    reduce waste

    reduce inventory and floor space

    create more robust production systems

    develop appropriate material delivery

    eje | June 2009 51st Land O'Lakes 70

    systems

    improve layouts for increased flexibility

    Responsibilities MatrixResponsibilities MatrixGroup Responsib le for Task Completion

    Project Task Form TT DV AS CQA PE QA QAV MF QAS

    Issue rocess/formulation

    comparison report N P I I

    Complete manufacturing

    master batch record N N,S P,A A A A

    Issue technical transfer

    document N,A P,A N N N,A A N,A I,A

    Generate validation

    master plan/protocols I N,A N N,A P,A A A

    FDA pre-approval

    inspection N N N N N N P N N N

    Manufacture validation

    eje | June 2009 51st Land O'Lakes 71

    Issue validation reportI N,A N,A A P,A A A

    P = Primary Responsibility

    N = Input Required

    A = Appr ova l

    I = Informed

    S = Support

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    Extra SlidesExtra Slides

    Validation

    eje | June 2009 51st Land O'Lakes 72

    Quality SystemsQuality Systems

    SPC

    Histograms

    SQC

    Quality Circles Check Sheets

    Pareto Charts

    Cause and EffectDiagrams

    Fishbone

    Ishikawa

    Defect Concentration

    TQM / TQC

    Quality One (Q1)

    ISO 9000...

    JIT

    Six Sigma

    eje | June 2009 51st Land O'Lakes 73

    Diagrams

    Scatter Diagrams

    Control Charts

    MAIC DFSS

    Lean Manufacturing

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    FDA: Process ValidationFDA: Process Validation

    Process validation is establishingdocumented evidence which providesa high degree of assurance that aspecific process will consistently

    produce a product meeting its pre-determined s ecifications and ualit

    eje | June 2009 51st Land O'Lakes 74

    characteristics.

    From FDAs GUIDELINE ON GENERAL PRINCIPLES OF PROCESS

    VALIDATION, May 1987

    Process ValidationProcess ValidationVIII. ELEMENTS OF PROCESS VALIDATION

    A. Prospective Validation

    .

    a. Equipment : Installation Qualification

    b. Process: Performance Qualification

    c. Product: Performance Qualification

    2. System to Assure Timely Revalidation

    3. Documentation

    eje | June 2009 51st Land O'Lakes 75

    . e rospec ve rocess a a on

    From FDAs GUIDELINE ON GENERAL PRINCIPLES OF PROCESS

    VALIDATION, May 1987

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    Conducting Process ValidationConducting Process Validation

    Three-batch validation at end ofdevelopment, i.e. in commercial

    Focus on facilities, equipment,components, methods, processqualification

    PV execution thereby provides thenecessary documentation to show product

    eje | June 2009 51st Land O'Lakes 76

    ,control

    Note: Failure to execute PV successfully reflectsincomplete understanding of the process