GMP Quality Control Module
GMP Quality Control Module
Approved by
ASEAN GMP Team
Endorsed by
ASEAN Cosmetic Committee
European Committee
for Standardization
Module 7
Implementing Agency GMP Workshop Kuala Lumpur 14-16 Nov 2005 1
Project co-financed by
European Union Project co- financed
by Asean
CONTENT OF PRESENTATION
Introduction
➢ Objective
➢ Scope
Quality Control Principle
➢ QC Overview
➢ QA versus QC
➢ General Principle
Basic Requirement of Quality Control
➢ Quality control unit
➢ Quality control laboratory
➢ Responsibility
Quality Control Documents
Tasks of Quality Control
References
European Committee
for Standardization
Module 7
Implementing Agency GMP Workshop Kuala Lumpur 14-16 Nov 2005 2
Project co-financed by
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INTRODUCTION
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INTRODUCTION
➢ Good Manufacturing Practice (GMP) is the part of Quality
Assurance that ensures that products are produced and
controlled consistently and reliably. This consistency of
production and control is essential. It can only come about by
having clear descriptions of the way in which the work will be
done.
➢ GMP specifically addresses risks of cross-contamination and mix-
up that cannot be fully controlled by testing of the final product.
➢ These risks can best be controlled by having a properly
managed system of working that takes them into account. This
means that the quality checking system must be designed with
these risks in mind and set out to find whether any errors have
occurred.
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OBJECTIVES
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SCOPE
➢ Quality control involved sampling, inspecting and
testing of starting materials, in process,
intermediate, bulk and finished products.
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Sampling
Inspection & testing of: Starting Material, Bulk, Intermediate, Finished product
Key Environment monitoring program Batch record review/documentation
Focus
Area Sample retention program Stability study Calibration Reagent Handling
Release/Reject: Control for materials & product disposition
QA VS QC
• The terms quality assurance and quality control are often used
interchangeably to refer to the actions performed for ensuring the
quality of a product, service, or process.
• Both terms, however, have many interpretations because of the
multiple definitions for the words "assurance" and "control."
• The definitions below, for example, point toward a specific distinction
between these two terms:
Assurance
Assurance := The
The actact of giving
of giving confidence, Quality assurance : All the planned and
confidence, the state
the state of being of or
certain, being certain,
the act of or systematic activities implemented within the
making
the certain.
act of making certain. quality system that can be demonstrated to
provide confidence a product or service will
fulfill requirements for quality.
GENERAL PRINCIPLES
➢ Each holder of a manufacturing authorization should
have a QC Department
➢ Independence from production and other departments
is considered to be fundamental
➢ Under the authority of an appropriately qualified and
experienced person with one or several control
laboratories at his or her disposal.
➢ If do not have any facility, it can be managed by
appointed respective external laboratory institution(s).
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BASIC REQUIREMENTS OF
QUALITY CONTROL
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BASIC REQUIREMENTS
Quality Control department should have :
resources:
➢ adequate facilities
➢ qualified personnel
➢ approved written procedures
tasks :
➢ sampling, inspecting, testing,
➢ releasing or rejecting
➢ monitoring
objects :
➢ Starting materials, intermediates, bulk, and finished products
➢ Returned products
➢ Environmental conditions
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QC LABORATORY
• There shall be QC laboratory attached to each manufacturing
unit.
• The laboratory shall be capable of performing all the test in
accordance to approve specification, or to perform part of test
while sub-contracting part of tests to approved contract
laboratory.
• Where appropriate, QC laboratories shall be separated from
production areas especially for microbiology lab.
• The laboratories should be designed to suit the operations to be
carried out in them. Sufficient space should be given to avoid
mix-ups and cross-contamination. There should be adequate
suitable space for sample and records.
• Separate rooms may be necessary to protect sensitive
instruments from vibration, electrical interference, humidity, etc.
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RESPONSIBILITIES
• Examines, approves or rejects incoming materials,
intermediates, bulk, the finished products, and returned
products.
• Does the inspection during production (in-process control)
• Establishes, standardizes, and implements all QC procedures,
and also establish the specification of each incoming materials.
• Establishes specification of intermediates, bulk and finished
goods together with head of Production.
• Approves reprocessing instruction and rework instruction
• Reviews production records to determine errors and ensures
that investigations have been conducted and corrective action
taken
• Involves in all decisions concern with the product quality
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OTHER RESPONSIBILITIES
Establishing, verification, and implementing all QC
procedures
Evaluating, maintaining, storing, and monitoring all
reference standards and retained samples
Reviewing batch documentation
Maintaining correct specification of materials and
finished products
Stability testing of each finished product
Participating in :
➢ complaint investigations
➢ environmental monitoring
➢ GMP training
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QC DOCUMENTS
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SPECIFICATION CONTROL
Each specification shall be approved, signed
and dated, and maintained by QC unit
The following specification shall be minimally
maintained and controlled:
➢ Starting materials specification
➢ Process water specification
➢ Intermediate or bulk product where applicable
➢ Finished product specification
➢ Master formula
➢ Batch Manufacturing Record (BMR)
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IN-PROCESS CONTROL
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TASKS OF
QUALITY CONTROL
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QC WORK FLOW
Start
Quarantine • Intermediates
• Incoming materials
• Bulks
• Water 2. Receiving • Finished goods
• Returned goods
• Environment monitoring
3. Sampling
QC/QA Status
4. Test samples
Lab
Quarantine
Records
5. Review of batch record
Release
Meet specification
NO 7. Non conformance or
Reject out of specification
YES investigation
6. Goods release
Release
8. Goods Reject
Reject
End
End
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RECEIPT
• There should be written procedure on the receiving,
internal labeling, quarantine and storage of starting
materials, packaging materials and other materials as
appropriate
• Upon receiving of the supplied goods, its identity,
legibility of batch number, integrity of its primary
packaging and seal shall be verified prior to acceptance.
• Certificate of Analysis shall be provided by the supplier
accompanying the receiving of starting materials
• Quarantine goods shall be segregated from “Release”
goods
• Reject goods shall be stored in a define area with
consideration of control access (eg. Locked area)
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SAMPLING
The sample taking shall be done in accordance
with written procedure that describe:
➢ The method of sampling
➢ The sampling tools used
➢ The amount of samples to be taken
➢ The type and condition of the sample container to be
used (ie amber glass bottle)
➢ The identification of the container sampled
➢ Special precaution for hazardous materials
➢ The storage condition (if any)
➢ Instruction for cleaning and storage of sampling
equipment
➢ Instruction for re-sealing the opened container.
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SAMPLING PROCESS
• Sampling tools such as knives, pliers, saws, hammers, wrenches,
implements to remove dust (preferably a vacuum cleaner)
• Material to re-close the packages (such as sealing tape), as well as self-
adhesive labels to indicate that a part of the contents has been
removed from a package or container.
• Containers due to be sampled should be cleaned prior to sampling if
necessary.
• There should be a written procedure describing the sampling operation.
This should include health and safety aspects of sampling.
• The container used to store a sample should not interact with the
sampled material nor allow contamination. It should also protect the
sample from light, air, moisture, etc., as required by the storage
directions for the material sampled.
• Microbiology sampling tools shall be sterilised prior to use
• Aseptic technique shall be used during sampling
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SAMPLING PLAN
1. Raw Material
Sampling plan for raw material should be based on defined
sampling standard, for example:
• the “n plan” is based on the formula n = 1+√N, where N is the
number of sampling units in the consignment;
• the “p plan” is based on the formula p = 0.4 √N, where N is the
number of sampling unit; or
• the “r plan” on the formula r = 1.5√N .
• reduce sampling plan such as “p plan” shall be considered only
when there is established confidence on the material’s
uniformity.
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SAMPLING TOOLS
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European Committee
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Project co-financed by
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Module 7
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CONTROL OF
European Union Project co- financed
by Asean
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for Standardization
Module 7
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Project co-financed by
CONTROL OF
European Union Project co- financed
by Asean
European Committee
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Module 7
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CONTROL OF
European Union Project co- financed
by Asean
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Module 7
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CONTROL OF
European Union Project co- financed
by Asean
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LABORATORY REAGENT
• Reagent should be prepared in accordance with written
procedures.
• Volumetric solution, the last date of standardization and the last
current factor should be indicated.
• Where necessary, the date of receipt of any reagents should be
indicated on the container. Instruction for use and storage
should be followed.
• Where necessary, the identification test and/or other testing of
reagent materials is required upon receipt or before use.
• Reagent to be certified by the original producer to the quality of
reagent grade purchased, typically a CoA shall be available for
review and verification on acceptance.
• Laboratory safety manual shall be available for safe operation of
the reagent and chemicals.
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LABORATORY REAGENTS
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CALIBRATION
• To maintain the accuracy and precision of test equipment
at all times.
• To ensure highest level of confidence in all measurement
that affect materials disposition decision, with unbroken
chain of traceability to national standard.
• To determine whether the equipment is still fit for its
intended purpose.
• It is based on the comparison of a primary standard or
instrument of known accuracy with another equipment (to
be calibrated)
• It is used to detect, correlate, report or eliminate by
adjustment of any variation in the accuracy of the
equipment being calibrated.
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EQUIPMENT CLASSIFICATION
Critical equipment:
➢ Direct measurement that affect the final product
quality
➢ Measurement on critical process parameters in
the process specification
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CALIBRATION INTERVAL
Depending on:
➢ Classification of Critical or non-critical
➢ Usage (light or heavy usage)
➢ Handling (light or heavy handling)
➢ Manufacturer’s recommendation
➢ Reference to NIST or accreditation body
guideline for a specific measurement system
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PRIMARY STANDARD
• Highest accuracy order in the
measurement system
• Traceable to National or
International standard
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REFERENCE STANDARD*/MATERIAL
• Reference Standard
It shall be calibrated by a body that can provide
traceability. Such reference standard of measurement
held by the laboratory shall be used for calibration
only. It shall be calibrated before and after any
adjustment
• Reference Materials
Where possible, it shall be traceable to SI units of
measurement, or to Certified Reference Materials.
Internal Reference Material shall be checked as far as
is technically and economically practical
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CALIBRATION RESULT
VERIFICATION
• Applicable to equipment that cannot be
calibrated (adjustment, correlation, etc)
• Verification against measurement standard
with correction factor documented
• Actual reporting of result shall include the
correction factor
• Temperature correction factor “- 2 0C”.
➢ Measured value: 240 C
➢ Reported value = 24 0 C –2 0 C= 22 0 C
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OUT OF CALIBRATION
• Remove equipment from use
• Out of Calibration Investigation to be carried
out to determine the source of inaccuracy
• Evaluate the impact of OOC result on the final
product quality and other previously
measured data
• All investigation findings should be
documented
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CALIBRATION RECORDS
• Calibration Master Plan
Include the control of all critical measurement
equipment that contain the following details
➢ Name
➢ Identification by model # and serial #
➢ Location
➢ Owner/Responsible
➢ Calibration Frequency
➢ Calibration due date
• Calibration Certificate
• Calibration Procedure
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CALIBRATION CERTIFICATE
• Name and address of contracted calibration
laboratory
• Name and address of client
• Description and identification of item calibrated
• Environment conditions when calibration was
made
• Date of receipt of instrument, date of
calibration and date of next calibration
• Calibration method
• Result of calibration
• Signature and title of person responsible for
the calibration
• External calibration contract shall be awarded
to Accredited by the nation institution
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CALIBRATION IDENTIFICATION
• Status of equipment calibration shall be
available and affixed to the equipment
where applicable.
• Equipment identification shall bear the
following information:
✓ name of equipment
✓ serial no.
✓ date calibrated
✓ status
✓ schedule of next calibration and
✓ initial/signature of the person who performed
the calibration
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REPROCESSING (1)
• Reprocessing includes both definitions of
Reprocessing and Rework
• Definitions
➢ Reprocessing: Subjecting all or part of the
batch/lot of an in-process bulk, intermediate or
product of a single batch or lot to the previous step
of the approved manufacturing/packaging process
due to failure to meet pre-determined specification.
➢ Rework: Subjecting all or part of the batch /lot of
an in-process bulk, intermediate or product of a
single batch or lot to an alternate manufacturing/
packaging process due to failure to meet pre-
determined specification.
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REPROCESSING (2)
• Complete OOS/Non-conformance investigation with risk
assessment on recovery decision, based on approved
procedure
• Reprocessing Instruction includes the following details:
Additional Ingredient where necessary
Reprocessing instruction
Responsibility
Sampling Plan
Acceptance Criteria
• Approval of Reprocessing Instruction by QC
• Where batch adjustment which is part of the In-Process
Quality Control, this should not be considered where
there is reprocessing.
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REPROCESSING PRODUCT
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RETURN (1)
• Definition- Finished product that has been
distributed and is being returned for reasons other
than a product complaint reason.
RETURN (2)
• A product may be reworked/reprocessed
provided the subsequent product meets
appropriate standards, specifications, and
characteristics.
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RETURN (3)
• If the reason for a product being returned implicates
associated batches, an appropriate investigation shall
be conducted.
• Procedures for the holding, testing, and reprocessing
of returned products shall be in writing and shall be
followed.
• The recovery rational shall be documented with
approval from the QC unit.
• Disposal of return goods shall be based on approved
procedure.
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REFERENCES
1. Guideline on ASEAN Cosmetic GMP (2003)
2. U.S. Food Drug Administration, Center for Food Safety Applied
Nutrition, Cosmetic Compliance program
3. NIST
4. WHO Guideline for Drinking Water Quality
5. EUDRALEX, Medicinal Products for Human and Veterinary Use :
Good Manufacturing Practice, ,Volume 4.
6. WHO, Good Manufacturing Practices: Starting Materials.
7. Ariffin F., Consultation to Discuss : Stability Studies in a Global
Environment.
8. International Pharmacopoeia
9. WHO Guideline For Sampling OF Pharmaceuticals and related
materials.
10. PDA Technical Report No. 13 revised, Fundamentals of an
Environmental Monitoring Program
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