Validation Master Plan

Doc # VMP 001

Version 1.0

June 2006 First Class Pharmaceuticals Pty Ltd Page 1 of 33




First Class Pharmaceuticals






VALIDATION
MASTER PLAN



Version No 3
June 2006

Approval of the Validation Master Plan


Validation Master Plan
Doc # VMP 001
Version 1.0

June 2006 First Class Pharmaceuticals Pty Ltd Page 2 of 33

Sign here after reviewing and approving the document, standards and schedules

Title Name Signature Date
Written By:
Validation Manager
Approved By:
Engineering Manager
Production Manager
Quality Assurance Manager
Quality Regulatory Environmental
Manager


Distribution List

Name Copy
Quality Assurance Manager Original
Engineering Manager 1
Production Manager 2
Quality Regulatory Environmental Manager 3
Laboratory Manager 4
IT Manager 5


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Validation Master Plan - Change History Record
Ver No. Section
Amended
Amendment Details Approved By Date of
Approval
01 N/A Original








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Table of Contents
1. Introduction .................................................................................................................... 5
2. Purpose and Scope.......................................................................................................... 5
3. Risk Management and Establishment of Validation Priorities....................................... 9
4. Validation Phases ........................................................................................................... 9
4.1 Design Qualification (DQ) ........................................................................................... 10
4.2 Installation Qualification (IQ) ...................................................................................... 10
4.3 Operation Qualification (OQ)....................................................................................... 11
4.4 Performance Qualification (PQ).................................................................................. 11
4.5 Certification.................................................................................................................. 11
5. Validation Documentation............................................................................................ 12
6. Validation Plans for New Projects, Products or Processes .......................................... 12
7. GMP Systems Expected to be Validated...................................................................... 13
8. Retrospective Validation Programs (Retrospective Reviews) .................................... 14
8.1 General Requirements .................................................................................................. 14
8.2 Services Retrospective Validation............................................................................... 14
8.3 Equipment Retrospective Qualification ....................................................................... 14
8.4 Existing Product Manufacturing Validation................................................................. 14
8.5 Filling/Packaging Process Retrospective Validation ................................................... 14
8.6 Establishment of Validation Priorities Risk Assessment .......................................... 14
8.7 Retrospective Validation of Computer Systems.......................................................... 14
9. Revalidation Programs (Routine Validation) .............................................................. 14
10. GMP Computer Systems .............................................................................................. 14
11. Cleaning Validation...................................................................................................... 14
12. Documentation Control and Archiving ........................................................................ 14
13. Validation Schedules .................................................................................................... 14
14. Change Control............................................................................................................. 14
15. Glossary of Terms ........................................................................................................ 14
16. Validation Guidelines List............................................................................................ 15
17. List of Attachments ..................................................................................................... 15
1 Organisational Chart
2 IQ Template
3 OQ Template
4 PQ Template
5 Validation Supplement/Change
6 Validation Deviation

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1. Introduction

The key document in an organisation's validation program is its Validation Master Plan (VMP). It
is divided into three parts:

Part A Validation philosophy, scope, responsibilities, guidance documents, training requirements,
validation phases, plans and documentation overview.
Part B Guidelines for validation plans and protocol preparation
Part C Schedules of Work.
This Validation Master Plan (VMP) summarises the overall intentions and approach to the
validation of the FCP site.
It is intended to be a working document and should be periodically updated by site
management responsible for the execution of validation.

The Validation Master Plan:

Identifies which items are subject to validation, periodic review or routine validation.
Provides schedules of validation.
Identifies appropriate standards and guidelines to be referenced.
Describes functional responsibilities.
Defines protocol preparation, execution and reporting responsibilities.
Provides general guidance for validation document format.

2. Purpose and Scope

2.1 Scope
The validation master plan covers services installation and commissioning, equipment
qualification, computer systems validation and process validation for a range of existing
processes. This includes:
critical (product contact) equipment qualification
critical computer systems validation
critical utility and services qualification
facility qualification
capital works projects (prospective validation)
validation of new, or changed, products and processes
QC laboratory equipment qualification

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QC laboratory test method validation
retrospective (annual) review of critical systems and processes
routine revalidation of critical systems

The validation master plan does not include specific methods, laboratory test programs or
specific acceptance criteria. These items should be covered in individual protocols.

2.2 Regulatory Standards
Validation and operations should be capable of meeting the following regulatory GMP standards.
Australian Therapeutic Goods Administration (TGA) cGMP The PIC/S Guide to Good
Manufacturing Practices and associated Annexes.

GMP Guidelines and cGMPs
PICS Recommendations on Preparation of Validation Master Plans, Installation and
Operational Qualification, Non Sterile Process Validation and Cleaning Validation 2001
PIC/S Guidance Good Practices for Computerised Systems in Regulated GXP
Environments
Annex 15 EU cGMP - Qualification and Validation
ISPE baseline Guide Pharmaceutical Water and Steam Guide
ISPE GAMP (Good Automated Manufacturing Practices) Guidelines Edition 4
Other Industry Standards and Guides
British Pharmacopoeia - current,
European Pharmacopoeia - current,
United States Pharmacopoeia - current,
FDA Guideline on General Principles of Process Validation
FDA Guide - Inspection of High Quality Water Systems
FDA Guide - Inspections of Validation of Cleaning Processes
FDA Guide - Inspection of Quality Control Laboratories
PDA Guide to the Validation of Computerised Systems



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2.3 Organisation, Authority and Responsibility
2.3.1 Validation Organisation
Validation is managed by the Quality Management Group. Validation schedules and performance
to validation plan(s) are presented at the Quality Meetings for review and action as appropriate.

The personnel shaded in the Organisational Chart shown in Attachment 1 take primary
responsibility for management of the validation. Validation teams are established as required to
carry out specific validation projects.

2.3.2 Authority and Responsibility
The Quality Assurance Manager takes overall responsibility for the validation program in
consultation with the Production Manager.

The following table details the authority and responsibility for each phase of the plan.

Table 1 Authorisations List
Activity Protocol &
Document
Prepn
Protocol &
Document
Approval
IQ Reports OQ
Reports
PQ
Reports
Final Report
Approval &
Certificatn
Design
Qualification
Project Team


Project Team
QA Manager
Prodn Mgr

-

-

-
Project Team
QA Manager
Prodn Mgr
Facility,
Services,
Equipment
Qualification
Project Team Project Team
QA Manager
Prodn Mgr
Project Team
Contractor
QA Mgr
Project Team
Contractor
QA Mgr

-
Project Team
QA Manager
Prodn Mgr
Process
Validation
Project Team Project Team
QA Manager
Prodn Mgr

-

-
Project Team
Contractor
QA Mgr
Project Team
Contractor
QA Manager
GMP
Computer
Systems
User Group
PC & LAN
Administrator
QA Manager
User Group
PC & LAN
Administrator
PC & LAN
Administrator
Contractor
QA Manager
User Group
PC & LAN
Administrator
Contractor
QA Mgr
User Group
PC & LAN
Administrator
Contractor
QA Mgr
User Group
PC & LAN
Administrator
QA Manager
Cleaning &
Sanitation
Programs
Project Team
QA Manager

Project Team
QA Manager
Prodn Mgr

-

-
Project Team
QA Manager
Prodn Mgr
Project Team
QA Manager
Prodn Mgr
Laboratory
Equipment
Qualification
QA Supr QA Supr
QA Manager
QA Supr
Contractor
QA Mgr
QA Supr
QA Manager

-
QA Supr
QA Manager
Test Method
Validation
QA Supr QA Supr
QA Manager
- -
QA Supr
QA Mgr
QA Supr
QA Manager

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2.3.3 Validation Training

Validation Principles Training

Validation training will be undertaken on an as needs basis but prior to the commencement of
validation activities such as executing protocol. The training will cover the following:
content, intent and scope of the VMP (this document)
preparing protocols - layout and content
executing protocols
recording and maintenance of raw data
making changes during validation projects
preparing validation reports - content and standards

Validation training will be given to all people involved in the above activities. It will also ensure
that personnel are familiar with the operation of plant and equipment.


GMP Training

Staff will be trained in the principles of GMP and on the job application of GMP as part of orderly
start up of process lines. Specialist training in the operation of equipment and performance of test
methods will be conducted as required.

The training will include, where applicable:
Regulatory Standards
Principles of Cleaning and Sanitation
Personnel Hygiene
Good Laboratory Practices
Good Manufacturing Practices
Company Documentation (SOPs and Batch Records)

Specific instructions on equipment operation and safety shall be conducted as part of Operational
Qualification.


Standard Procedures Training

Training in the application of specific Standard Operating Procedures (SOP) will occur as part of
the start up of operations. Training will be verified as part of equipment qualification, cleaning
validation and process validation.


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3. Risk Management and Establishment of Validation Priorities

The scope of the validation activities relates directly to the risk assessment. The following
definitions are used to identify priorities in the Validation Schedules (Part C):
Validated
Validation Not Required or Not Applicable.
To Be Assessed in the next 12 months (TBA)
Requires Validation in the current planning period (RV)

These decisions, and all assumptions upon which they were made, should be documented and filed
by Quality Assurance.
4. Validation Phases
Validation is an activity that involves establishing documented evidence that a process does what it
purports to do based on a plan. Prospective Validation usually takes place in five distinct phases:
1. Design Qualification (DQ)
2. Installation Qualification (IQ)
3. Operation Qualification (OQ)
4. Performance Qualification (PQ)
5. Certification


User Requirements
(Process oriented descriptions
)
PQ
OQ
IQ
Design Specification
(Detailed Technical
Documentation )
Functional Requirements
(
What? How?)
Implementation
DQ
(Audits &
Reviews)
is based on
is based on
is based on
Commissioning





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4.1 Design Qualification (DQ)
4.2 Installation Qualification (IQ)

IQ (Installation Qualification) ensures that what has actually been provided complies with the
Design Specification. IQ establishes that:
operational and maintenance documents are present and registered,
product contact surfaces are finished to pharmaceutical standards and clean
support utilities and lubricants are reviewed and compliant,
installation, hookup is complete and satisfactory (as determined by a physical inspection),
safety and inspection are complete and satisfactory (as determined by a physical
inspection),,
software interfaces and controllers are documented and connected,
instrument calibration is complete,
preventative maintenance requirements are documented and complete,
training on equipment and safety is complete,
deficiency reports are reviewed and closed out
Installation Qualification (IQ) protocols are customised from a general template (refer
Attachment 2). Specific IQ protocols should be prepared for major utilities, computerised systems
and for individual items of equipment. Guidelines are included in Section B of this document.

A report summarising the results of IQ should be written, reviewed and approved.


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4.3 Operation Qualification (OQ)

OQ (Operation Qualification) verifies that the equipment or process does operate as described in
the Functional Requirements. It may commence before IQ reports are written but should not
commence before the IQ is substantially completed. Allowance for what minimum checks are
required before OQ can commence shall be stipulated in the Validation Plan and/or IQ Protocol.

OQ establishes that:
utilities and services have been installed and qualified,
critical instruments have been calibrated,
equipment control function tests have been qualified,
control over critical operating variables have been established and all tests have passed,
final commissioning trials under operational conditions are satisfactory and all tests have
passed,
standard operating procedures have been published,
safety conditions, alarms and controls have been qualified,
deficiency reports have been reviewed and closed out,
IQ report has been prepared and completed.
Operational Qualification (OQ) protocols are customised from a general template (refer
Attachment 3). The test case/test plans must be specific for the item under qualification. Specific
OQ protocols should be prepared for major utilities, computerised systems and for individual items
of equipment. Guidelines are included in Section B of this document.

IQ and OQ may be combined into the one document. This is suitable when the work is being
carried out by the same people and immediately following IQ.

A report summarising the results of IOQ should be written, reviewed and approved.

4.4 Performance Qualification (PQ)

4.5 Certification
Before the facility, equipment or process can be handed over to Production for routine operations, a
formal report must be written summarising the results of all validation activities, and a validation
status assigned and a Certificate issued.

It may be that not all results are available, or that some deficiencies or other issues are still
outstanding when production requirements necessitate using the facility, equipment or process.
These situations must be foreseen and allowed for within the Validation Plan or Protocol, an
Interim Report prepared and an Interim Certificate Released.


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5. Validation Documentation
5.1 Preparation of Protocols and Specifications.

5.2 Support Documentation
5.2.1 Protocol Supplement or Variation (refer Attachment 5)
During the course of validation there may be a need to update or amend protocols. This shall be
done via protocol supplements, rather than re-issue of new protocols.

5.2.2 Deficiency Report (refer Attachment 6)
During the course of validation activity deficiencies may arise. These should be documented
according to a deficiency report.


6. Validation Plans for New Projects, Products or Processes

6.1 Introduction
6.2 Publication and Control of Validation Schedules

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7. GMP Systems Expected to be Validated

Area or GMP System List of GMP Critical Systems Expected to be Validated
Facility Qualification
(GMP Room Commissioning)
As required by new project plans. The following rooms should be
qualified:
Raw materials and finished products storage
Dispensaries and sampling areas
Equipment washing, preparation and storage rooms
Component (bottles, caps etc) preparation areas
Manufacturing areas
Filling areas
Packaging area
Services Qualification

Process Equipment
Qualification

Process Validation

GMP Computer Systems

Cleaning & Sanitation
Programmes

Laboratory Equipment
Qualification

Test Methods


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8. Retrospective Validation Programs (Retrospective Reviews)
8.1 General Requirements
8.2 Services Retrospective Validation
8.3 Equipment Retrospective Qualification
8.4 Existing Product Manufacturing Validation
8.4.1 General Strategy
8.5 Filling/Packaging Process Retrospective Validation
8.6 Establishment of Validation Priorities Risk Assessment
8.7 Retrospective Validation of Computer Systems

9. Revalidation Programs (Routine Validation)
10. GMP Computer Systems
11. Cleaning Validation
12. Documentation Control and Archiving
13. Validation Schedules
14. Change Control
14. Glossary of Terms

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15. Validation Guidelines List
Part B of this document provides validation guidelines to assist protocol writers in the preparation
of protocols. The guidelines are NOT mandatory standards but represent the current expectations
of Quality Assurance. Alternative approaches are acceptable. The guidelines should be updated as
experience is gained or industry expectations change. The list of validation guidelines include the
following:

Guideline
#
Title
1 Design Qualification GMP Design Review and Qualification of Specifications
2 Construction Documentation and Quality Assurance New Facilities
3 Installation Qualification and GMP Room Finishes New Facilities
4 Operational Qualification of GMP Manufacturing Rooms
5 Critical Utilities - Heating, Ventilation and Air Conditioning (HVAC)
6 Qualification of Process and Purified Water Systems
7 Qualification of Compressed Gases Systems (Air and CO
2
)
8 Qualification of New Manufacturing Equipment General Approach
9 (Re) Qualification of Existing Manufacturing Equipment General Approach
10 Computer Validation
11 Guidelines for Process Validation
12 Guidelines for Conducting Retrospective Process/Product Review and Verifications
13 Guidelines for the Content of Process Validation Protocols
14 Guidelines for the Content of Process Validation Reports/Executive Summaries
15 Support Systems - Calibration and Preventative Maintenance Programs
16 Guidelines for Equipment Cleaning Programs - CIP and Manual
17 Validation of Quality Control Testing Procedures

17. List of Attachments
1 Organisational Chart
2 IQ Template
3 OQ Template
4 PQ Template
5 Validation Supplement/Change
6 Validation Deviation