Quality by design (QbD)

Prepared By:- Ms. Mali Sunayana M.
Asst. Professor
Subject:- Pharmaceutical Quality Assurance
Sahyadri College Of Pharmacy, Methwade, Sangola.
UNIT-I TOPIC-IV

 The pharmaceutical QUALITY BY DESIGN [QbD] is a systematic approach
to development that begins with predefined objectives and emphasizes product
and process understanding and process control, based on sound science and
quality risk management.
 Pharmaceutical manufacturers take several steps to make sure they produce
good quality products Yet, it has been found that several concerns plague the
drug development and manufacturing processes.
 The pioneer in quality, Dr. Joseph M. Juran was the first to develop the
concept of Quality by Design (QbD). He proposed that quality must be designed
into the product: if this is done, there will not be any of the quality crises that one
commonly encounters.
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 In a report titled, ‘Pharmaceutical Quality for the 21st Century: A Risk-
Based Approach’ the US Food and Drug Administration (FDA) furthered these
ideas, and provided an initiative to address quality issues.
 Through collaboration with major pharma companies, the FDA created a set
of guidance documents on the concept of Quality by Design (QbD).
 These were then accepted by the International Conference on Harmonization
(ICH) to streamline and regulate the process of drug development and
regulatory tiling related to drug manufacture.
 The main idea behind the QbD concept is that a process must be designed to
produce quality products. This becomes possible only when the process and
product are both thoroughly understood, and the risks involved in its
manufacturing are studied carefully, and steps are outlined to mitigate such
risks. This QbD approach is significantly different from the traditional,
empirical approach that emphasized on testing of quality in the end products.
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 The ICH guideline Q8 (R2) Pharmaceutical Development defines the term
quality by design (QbD) as,
“A SYSTEMATIC APPROACH TO DEVELOPMENT THAT BEGINS
WITH PREDEFINED OBJECTIVES , EMPHASIZES PRODUCT PROCESS
UNDERSTANDING AND PROCESS CONTROL, BASEDE ON SOUND
SCIENCE AND QUALITY RISK MANAGEMENT.”
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Design a Quality
Product
Quality of Mfg
Process
Product should meet
patients needs
Product development
may vary between
products
AIM of QbD
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 Some of the key objectives of QbD include:
 Achieving meaningful quality specifications for the product on the basis of
clinical performance.
 Enhancing process capability, and reducing product defects and variability by
improving the process and product design and control.
 To promote root cause analysis and manage any changes of drug product after
it has been approved.
 To improve efficiency of the processes involved in product development and
manufacturing.
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• Thus, In pharmaceutical QbD approach, First critical quality
characteristics need to be identified.
• These characteristics are then translated into critical quality attributes
(CQAs) of the drug product.
• Next a relationship is established between manufacturing process
variables and CQAs.
• Successful control of these variables ensures the consistent delivery of
a quality drug product with all desired CQAs to the patient.
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ICH
document
Subject Details
ICH Q8 (R2) Pharmaceutical Development Drug product development
using science principles.
ICH Q9 Quality risk Management How to assess, control, review
and manage quality risks.
ICH Q10 Pharmaceutical Quality system Quality systems, how to
improve process performance
and product quality.
ICH Q11 Development and Manufacture
of drug substances ( chemical
entities and biotechnological /
biological Entities)
How to select starting materials,
validate processes and control
them.
ICH Q12 Technical and regulatory
considerations for
pharmaceutical product
lifecycle management
Regulatory factors in
pharmaceutical products and life
cycle change management.
ICH DOCUMENTS ON WHICH QBD IS BASED
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1. Quality Target Product Profile (QTPP):- It identifies the CQAs of drug
product.
2. Product design and identifying Critical Material Attributes (CMAS).
3. Process design and identifying Critical Process Parameters (CPPs). This
includes linking the CMAs and CPPs with CQAs.
4. Controls strategy: developing specifications for active pharmaceutical
ingredients (APls), excipients and final drug product; also controls for every
step of the production process.
5. Process capabilities and continued improvement.
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FLOW OF EVENTS IN QbD
Define desired
product outcomes
Identify product
CQAs
Study impact of
CMAs on CQAs
Identify CPPs
Identify
Sources of
Variations,
Control them
Continual
monitoring to
ensure consistent
quality
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Quality Target Product Profile (QTPP):
QTPP is a summary of the quality parameters that must be present in the drug
product to ensure the desired quality is achieved. This is the basis on which
product design will commence. When formulating the QTPP, the points to be
considered include:
1. The intended use of the product, its route of administration, desired dosage
form and system used for drug delivery.
2. Strength of the dose.
3. Container-closure system to be used.
4. Release of the therapeutic component and factors that will influence
pharmacokinetic parameters (such as dissolution of drug) in the proposed dosage
form.
5. Quality criteria for the final product stability, purity, sterility, drug release etc.
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• After finalizing the QTPP, it is possible to identify the CQAs of the drug
product. CQAs are properties of the finished product - physical, chemical,
biological or microbiological - that must lie within certain range, limits or
distribution, in order to ensure that desired quality of product is attained.
• Some examples of quality attributes of drug products include identity of
drug, assay values, content uniformity, drug release profile, degradation
products, microbial levels, moisture content and physical properties such as
size, colour, shape and friability. Not all of them may be critical attributes.
•Whether an attribute is critical or not depends upon m. severity of the damage
that will be caused if the product fails outside the acceptable rang for that
particular attribute.
CRITICAL QUALITY ATTRIBUTES (CQAS):
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PRODUCT DESIGN:
A well designed product is one that meets patients requirements and this can be
confirmed through clinical studies. Such a product will maintain its performance
throughout its shelf life, and this can be confirmed by stability studies. Thus, product
design must be geared towards developing a robust product that delivers the desired
QTPP over the entire shelf life of the product.
For good product design, it is important to study the following in detail:
1. Physical, chemical and biological characteristics of the drug (examples: particle
size, polymorphism, solubility, melting point, pKa, oxidative stability, partition
coefficient, bioavailability, membrane permeability etc.).
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2. Type of excipients and their grade, and details of intrinsic excipients variability
(common excipients such as binders, diluents, disintegrates, glidants, colouring
agents. sweeteners, suspending agents, film coatings, preservatives, flavours etc.).
3. Interactions of drug substances with excipients by carrying out drug- excipient
compatibility testing.
4.The critical material attributes (CMAs) of both drug and excipients to ensure
development of a robust formulation.
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• CMA:-
Physical, Chemical, Biological or Microbiological of raw material that
must lie within appropriate limits or range to ensure desired quality.
• CQA:-
Physical, chemical, biological or microbiological characteristics of drug
product intermediates or finished drug products that must lie within
appropriate limits or range to ensure desired quality.
• PROCESS DESIGN:
• Manufacturing process for a drug product is made up of a set of unit
operations run in a particular sequence, to give the final product.
• The term unit operation refers to any activity where there is a physical or
chemical change in the substance.
• Milling, mixing, granulation, drying, tablet compression, coating, are all
examples of unit operations in tablet manufacture.
:-
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Processes must be designed in such a way that each unit operation is performed as
expected to deliver the necessary product.
For this, it is important to:
(a) Identify the critical causes of variations.
(b) Manage these variations during the process.
(c) Predict quality attributes of the product with accuracy and reliability.
Any parameter whose variability can have an adverse impact on a CQA, is critical
to the process, and called as Critical Process Parameter (CPP).
All CPPs for a given process must be first identified; then they must be monitored
and regulated to make sure that desired quality products are produced.
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• CONTROL STRATEGY:
-The data generated during developmental studies must be used to set up a control
strategy.
LEVEL 1:-
Automated engineering controls are used for real –time monitoring of CQAs of the
output materials.Process Analytical Technology (PAT) systems are .. example of this
type of control.
LEVEL 2: -
Here, the emphasis is on understanding the process and product, and designing, it
with control over the pharmaceutical process.
LEVEL 3:-
This strategy depends on detailed testing of end-product as seen in conventional
pharmaceutical manufacturing.
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• PROCESS CAPABILITY AND CONTINUED IMPROVEMENT:
• Process capability is a measure of the level of inherent variability shown by a
stable process that is under control, when compared with the established acceptance
criteria .
• Variability may be short-term or long-term, and the QbD program must result in
identification and reduction of the variations that impact the quality of product.
• Continuous improvement methods need to be adopted to remove these sources of
variability. This includes several activities in different phases such as:
1. Defining the problem and setting up specific goals.
2. Measuring key areas of the process and collecting necessary data.
3. Data analysis to find cause-effect relationships.
4. Use results of data analysis to optimized the process.
5. Perform pilot runs to check optimized process capabilities.
6. Monitor processes to make sure they stay in a state of statistical control.
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Quality by Design relies on the use of certain tools. These include prior
knowledge, risk assessment, mechanistic models, design of experiments and data
analysis, and process analytical technology.
PRIOR KNOWLEDGE:
As per ICH guidelines, prior knowledge is the information or knowledge or skills
that have been acquired through previous experience of similar processes and
published information.
This tool can be used at the beginning of the developmental process and may be
regularly updated using data generated during the process.
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RISK ASSESSMENT:-
- As per ICH Q9, quality risk management must be done before development
studies to detect the high-risk variables that have an impact on drug product
quality.
-Risk evaluation must be done on the basis of scientific knowledge and is often
used to determine critical variables.
-These variables must then be further investigated through experimentation, so
that a control strategy may be established.
- Some of the common risk assessment tools used are flowcharts, fault tree
analysis, failure mode effects analysis, hazard analysis and critical control points,
risk ranking and filtering etc.
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• DESIGN OF EXPERIMENTS:-
- This tool involves setting up a series of structured tests where changes to the
variables of a process are made in a planned manner. Then, the impact of these
changes on a chosen output is assessed.
• PROCESS ANALYTICAL TECHNOLOGY (PAT):-
The US FDA defines PAT as "A system for designing, analyzing. and controlling
manufacturing through timely measurements ( i.e., during processing) of critical
quality and performance attributes of raw and in-process materials and processes
with the goal of ensuring final product quality.
PAT allows real-time monitoring of CMAs, CPPs or CQAS to demonstrate that
the process is in a state of control.
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1. Better assurance of product quality duo to improved process design and
better risk management during the manufacturing process.
2. Innovation and increased efficiency and reduced potential for errors load
to cost savings.
3. Improves regulatory compliance and streamlines change management.
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1. Requires cultural change in the organizational approach to quality.
2. Expensive, requires management support.
3. Calls for collaboration between departments and there may be
resource/workload limitations.
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1) A Text book of Pharmaceutical Quality Assurance by the
author Anusuya R.Kashi, Bindu Sukumaran, And Veena P.
Nirali Prakashan. Page No.4.1- 4.8
2) www.google.com

Quality by design (QbD)

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