Validation master plan

Validation Master Plan
Dr. A. Amsavel

Presentation Overview
1. Definition
2. Qualification and Validation
3. Qualification
4. Validation
Process Validation
Cleaning Validation
Analytical method
5. Change Control
6. Revalidation

Definition
Validation Master Plan- PIC/S
 A document providing information on the
company’s validation work programme.
 It should define details of and timescales for the
validation work to be performed.
 Responsibilities relating to the plan should be
stated.

Definition
Validation Master Plan. (WHO guideline):
 The validation master plan is a high-level document
that establishes an umbrella validation plan for the
entire project and summarizes the manufacturer’s
overall philosophy and approach.
 It provides information on the manufacturer’s
validation work programme and deﬁnes details of and
timescales for the validation work to be performed,
including a statement of the responsibilities of those
implementing the plan.

Qualification or validation?
A system must be Qualified to operate in a
Validated process:
Qualify: a system and/or equipment
Validate: a process
E.g. Qualify an autoclave, whereas you validate a
Sterilisation process

Definition
Qualiﬁcation:
Documented evidence that premises, systems or
equipment are able to achieve the predetermined
specifications properly installed, and/or work correctly
and lead to the expected results
Validation.
Action of proving and documenting that any process,
procedure or method actually and consistently leads to
the expected results.

Validation Master Plan (VMP)
1. Qualification and Validation
2. Planning for Validation
3. Documentation
4. Qualification
5. Process Validation
6. Cleaning Validation
7. Change Control
8. Revalidation

Purpose of VMP
The VMP should present an overview of the entire validation
operation, its organisational structure, its content and planning.
A VMP helps management:
- to know the validation plan –plan for time, people & money, and
- understand the necessity for the programme;
A VMP helps all members of the validation team:
- to know their tasks and responsibilities.
A VMP helps GMP inspectors:
- to understand the firm's approach to validation and
organisation of all validation activities.
- Organisational structure, its content and planning.

Is it one time activity?
 Qualification and validation can not be considered
once-off exercises, For example, the start-up of a new
manufacturing operation.
 It is an ongoing programme should follow its first
implementation.

VMP procedure
 Purpose & Scope
 Responsibility
 Validation policy
 Qualification of facilities, systems, equipment & utilities
 Validation: Process, cleaning, analytical methods & CSV
 Personal qualification
 Documentation format: Protocols and Reports
 Requalification & revalidation: while change & periodic
 planning and scheduling;
 change control – Qualification and Validation based on risk
 Reference to existing documents.
 Validation schedule
User requirement specifications
The requirements and specifications for the utility or equipment should be defined by the user and documented in the URS.
The URS should be used when selecting the required utility or equipment from an approved supplier, and to verify suitability throughout the subsequent stages of q

Qualification of Facility, Equipment & system

Qualification
 Design Qualification: Documented verification that the
proposed design of facilities, systems and equipment is
suitable for the intended purpose.
 Installation Qualification: Documented verification that
the installations (such as machines, computer system
components, measuring devices, utilities and
manufacturing areas) used in a processor system are
appropriately selected and correctly installed in accordance
with established specifications.

Qualification
 Operational Qualification: Documented verification
that the system or subsystem operates as intended over all
anticipated operating ranges.
 Performance Qualification: Documented verification
that the equipment or system performs consistently and
reproducibly within defined specifications and parameters
in its normal operating environment (i.e. in the
production environment)

Develop a Validation Master Plan
Qualification Purpose
Design
Qualification
(DQ)
Design specifications to ensure that all specified design elements have been
included and that
 the design meets the relevant regulatory and statutory requirements.
Installation
Qualification
(IQ)
Verifies that
 the equipment/system/process is installed correctly,
 supplied as specified,
 integrated into the site calibration and maintenance systems and available
for use.
Operational
Qualification
(OQ)
Verifies that
 the equipment/system/process is operating correctly,
 compliant with functionality requirements and
 integrated into the systems and QMS.
Performance
Qualification
(PQ)
Verifies that
 the equipment/system/process is continuously meeting performance criteria
for routine use and
 performing adequately for routine use in commercial production.

Design qualification
 DQ should provide documented evidence that the
design specifications were met and are in accordance
with the URS.
User requirement specifications :
Consider the following for URS;
 Product Requirements
 Process & Operation Requirements
 Operating Ranges
 GMP, Operation & Safety Requirements

URS:
 The requirements and specifications for the utility or
equipment should be defined by the user and
documented in the URS.
 The URS should be used when selecting the required
utility or equipment from an approved supplier, and to
verify suitability
Factory Acceptance Test and Site Acceptance Test
 Where appropriate, FAT and SAT should be performed
to verify the suitability of the system at site, prior to
the subsequent stages of qualification.

Eg: Hydrogenation Reactor:
User requirement Design Component
1. Process material Acidic MOC- GL/ hastaloy
2. Immiscible liquids Turbine type agitator
to be mixed for rxn & higher RPM ?
3. High pressure hydrogenation Pressure rating ?
4. No gas leakage Mechanical seal
5. Safety issue Rupture disc/Safety value
6. Oil in thermowel Food grade oil (GMP)
etc..

Installation Qualiﬁcation
IQ should include, but not be limited to the
following:
 Installation of equipment, piping, services and
instrumentation check to current engineering
drawings and specifications;
 Verification of materials of construction.
 Calibration requirements;
 Collection and collation of supplier operating
procedure/WI and maintenance requirements;

Installation Qualiﬁcation
Demonstrate that equipment has been Installed as per
design and installation requirements.
Installation check list:
 Civil requirements
 Electrical
 Production
 Measuring instruments
 Utilities & Piping
 Safety Issues
 Operation manuals & SOPs
 Critical stages
 Spare parts list etc

Operational qualification
OQ should include, but not be limited to the following:
 tests that meets the functionality requirement of processes,
systems and equipment;
 tests to include a condition or a set of conditions
encompassing upper and lower operating limits, and
“worst case” conditions.
 finalisation of calibration, operating and cleaning
procedures,
 operator training and preventative maintenance
requirements.
 Conclusion to approve/ release the facilities, systems and
equipment.

Operational qualification
To demonstrate that the equipment will perform as
per design within specified parameters.
 Define critical tests for OQ with Acceptance criteria
 Prepare testing procedures to cover upper and lower
operating limits
 Calibrate measuring devices
 Operation & Cleaning procedure
 Preventive maintenance plan
 Prepare OQ report

Performance qualification
PQ should include, but not be limited to the
following:
 test, using production materials, qualified substitutes or
simulated product,
 test to include a condition or set of conditions
encompassing upper and lower operating limits.
 Although PQ is described as a separate activity, it may in
some cases be appropriate to perform it in conjunction
with OQ.
 Also considered as process validation

Documents
URS
Purchase orders
Engineering drawings
MOC certificates
test certificates & tractability certificates
Operating manuals
Calibration procedures & certificates
Safety instructions
Qualification protocol & Reports etc

Process Validation
1. Prospective validation
2. Concurrent validation
3. Retrospective validation
 Revalidation as required

Process validation
To Demonstrate with Documented Evidence that a
Specific ‘Manufacturing Process’ is Capable of
Performing in a Reliable and Consistent Manner to
Deliver a Homogenous Product Meeting Defined
Quality Attributes Consistently.
Purpose:
 High degree of assurance
 Consistency
 Documented proof
 Built-in Quality

Process Validation
 Process validation should normally be completed prior
to the distribution and sale of the medicinal product
(prospective validation).
 In exceptional circumstances, where this is not
possible, it may be necessary to validate processes
during routine production (concurrent validation).
 Processes in use for some time should also be validated
(retrospective validation).

Process Validation : Pre-requirement
The following shall be ensured prior to Process
validation;
 Facilities, systems and equipment to be used are qualified
 Instruments are calibrated
 Analytical testing methods are validated.
 Process is reviewed and ready (development report with
QbD concept)
 Protocol is prepared , reviewed and approved.
 Personnel involved in the validation are appropriately trained.

Prospective Validation
 It is establishing documented evidence prior to process
implementation that a system what it purports to do based
on a preplanned protocol.
 It is conducted prior to distribution of either a new product
or a product made under a modified Production process,
where modifications are significant and may affect product
characteristics.
 This is a preplanned scientific approach and includes
initial stages of equipment validation.

Concurrent Validation
 It is establishing documented evidence that a process does
what it purports to do, based on information generated
during actual implementation of the process.
 It may be practical approach under certain circumstances.
 When a previously validated process is being transferred
to a third party contract manufacturer or to another
manufacturing site .
 When number of batches produced are limited.
 Revalidation due to changes eg Increase batch size

Retrospective Validation
It is establishing documented evidence that a system does what
it purports to do, based on review and analysis of historical
information. It has become synonymous with achieving
validation by documenting all historical information, e.g.
release data for existing products and using that data to
support position that process is under control.
 where the process ; Critical quality attributes and critical
process parameters have been identified; controls have been
established;
 There have not been significant process/product failures
attributable to causes other than operator error or equipment
failures unrelated to equipment suitability;
Evaluate : Min 30 batches and Cpk within the limit

Validation protocol contents
‒ the objectives & Scope;
‒ the responsible personnel
‒ description of the SOPs
‒ equipment or instruments to
be used;
‒ calibration requirements;
‒ standards and criteria as
appropriate;
‒ the stage of validation
‒ the critical processes
parameters; critical
operations
‒ sampling, testing and
monitoring requirements;
additional test
‒ stress testing where
appropriate;
‒ predetermined acceptance
criteria
‒ review and interpretation of
results;
‒ deviations
‒ conclusion

Re-validation
Revalidation.
 Systems and processes should be periodically
evaluated to verify that they are still operating in a
valid manner.
 Repeated validation of a previously validated
system (or a part thereof) to ensure continued
compliance with established requirements.

Cleaning Validation
 Equipment and utensils shall be cleaned, maintained and
sanitized at appropriate intervals to prevent contamination
that would alter the safety, identity, strength, quality or
purity of the drug product.
 Pharmaceuticals can be contaminated by potentially
dangerous substances
 Essential to establish adequate cleaning procedures
 “Cleaning validation should be performed in order to
confirm the effectiveness of a cleaning procedure” (PIC/S)
 “The data should support a conclusion that residues have
been reduced to an ‘acceptable’ level” (FDA)

Cleaning Validation
Strategy on cleaning validation
 Product contact surfaces
 After product changeover
 Between batches in campaigns
 Bracketing products for cleaning validation
 Periodic re-evaluation and revalidation

Cleaning Validation
Cleaning Validation protocol:
 Objective of the validation
 Responsibility for performing and approving validation study
 Description of equipment to be used
 Interval between end of production and cleaning, and
commencement of cleaning procedure
 Possible residues
 Cleaning procedures to be used (Parameters to be
monitored/controlled)
 Number of cleaning cycles performed consecutively
 Sampling procedures used and rationale Sampling locations (Rinse
and Swab )
 Testing method for residue
 Acceptance Limits with Justifications

Analytical Method validation
Analytical Method shall be validated for it of indented
purpose or verified for it suitability
Method validation is the process of planned and systematic
study to confirm that it is suitable for its intended use.
 Method is reliable, accurate & reproducible

Validation Parameters/characteristics
 Accuracy
 Precision
 Repeatability
 Intermediate Precision
 Specificity
 Linearity
 Range
 Detection Limit
 Quantitation Limit
 Robustness

Analytical procedure
Characteristics
Identificat
ion
Tests for impurities Assay
Quantita
tive Limit test
Accuracy No Yes No Yes
Precision- Repeatability No Yes No Yes
Intermediate precision No Yes No Yes
Specificity Yes Yes Yes Yes
Limit of Detection No Yes Yes No
Limit of Quantitation No Yes No No
Linearity No Yes No Yes
Range No Yes No Yes
Robustness * No Yes No Yes
Characteristics to be validated

Computerized Systems Validation
1. GMP-related computerized systems should be validated.
validation depends on the diversity, complexity, and criticality of the
computerized application.
2. Appropriate installation and operational qualifications should
demonstrate the suitability of computer hardware and software
to perform assigned tasks.
3. Computerized systems should have sufficient controls to prevent
unauthorized access or changes to data. There should be controls to
prevent omissions in data (e.g., system turned off and data not captured).
4. Written procedures should be available for the operation and
maintenance
5. Where critical data are being entered manually, there should be
an additional check on the accuracy of the entry.
6. Changes to computerized systems should be documented and
validated/ tested
7. A back-up system should be provided.

Water system design
Water system design
1. Constructed of suitable materials such as stainless
steel
2. Polished surface & proper welding to prevent
microbial film
3. Sanitary fittings & connections
4. Pipes sloped so water does not pool and can drain
easily
5. Circulate the water
6. Incorporate non-return valves (NRV)

Water system
The water system documents should have
 Valves / Sampling points
 drain points
 instrumentation
 flow rates/ velocity
 Schematic diagram
Validation for water systems consists of three phases
 Phase 1: 2 – 4 weeks
 Phase 2: 4 weeks
 Phase 3: 1 year

Changes that require revalidation
 Software changes/controllers
 Site changes
 Operational changes
 Change of source of material
 Change in the process
 Significant equipment change
 Production area changes
 Support system changes

VMP
VMP should contain at least:
 Validation policy
 Organizational structure
 Identifies validation items (products, processes,
systems)
 Summary of facilities, systems, equipment,
processes to be validated
 Documentation format for protocols and reports
 Planning and scheduling
 Change control
 Training requirements

VMP
VMP should state who is responsible for:
 Preparing the VMP
 The protocols and SOPs
 Validation work
 Report and document preparation and control
 Approval/authorisation of validation protocols
and reports in all stages of validation process
 Tracking system
 Training needs in support of validation

VMP
VMP should contain:
 Validation list/plan with timelne (What to validate)
 Specific process considerations
 Specific characteristics briefly outlined
 premises, systems and equipment
 processes
 products
 Cleaning
 Analytical method etc

Reference
 https://www.picscheme.org
 www.who.int/medicines/areas/.../validation-
without_appendices_2016_05_17.pdf
 https://ec.europa.eu/health/sites/health/files/files/pharmacos/docs/d
oc99/gmpanx15_en.pdf
 https://www.validation-online.net/user-requirements-
specification.html
 www.usp.org
 www.ich.org
 www.fda.gov/cder/

Validation master plan

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Validation master plan