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Change Control goes to the core of pharmaceutical operations. Most FDA 483 observations are written to cite a lack of control of the plant. If change control is weak, the plant is out of control. What changes are worth spending a lot of time effecting and what changes can be made effective by an individual acting in accordance with their assigned duties? This is the question that compliance and regulatory people have pondered for a long time. The cost implications can not be underestimated by simply stating that all changes are critical and therefore need to have a lot of paper work to effect and ever increasing costs to maintain the status of the change control.
Our Approach
Determination of Criticality and Complexity
Determination of criticality and complexity is essential to assessing the appropriate level of change control. A matrix system for determination of the appropriate change control level is a useful tool for making this assessment. The first matrix is the criticality determination. If the assessment of the effort results in any one the four major categories on the left placing the effort into the high or very high columns then the entire effort is placed in this level of criticality or complexity.
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LIFE CYCLE PHASES
(Lower Level Procedures will be more specific.)
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Level 1
Validation or Change
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Level 2
Validation or Change
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Level 3
Validation or Change
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Level 4
Validation or Change
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PROJECT TEAM
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Project Leader
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Project Leader selects team
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Project Leader
Validation Engineer
Other team members as needed
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Project Leader
Validation Engineer
Cross-functional Reps.
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DEVELOPMENT & DESIGN
(Document design)
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Design Notes
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Formal Requirements
Feasibility Study
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Formal Requirements
Feasibility Study
Design Review
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Formal Requirements
Feasibility Study
Failure Analysis
Design Review
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IMPLEMENTATION
FABRICATION/CODE
(Documents needed to maintain the system)
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Drawings
Documented Code
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Drawings
Documented Code
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Drawings
Documented Code Connectivity Diagrams
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Drawings
Documented Code
Connectivity Diagrams
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TESTING / QUALIFICATION
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Test Report
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Test Plan written by Project Team
Test Results
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Test Plan written by Project Team & Approval by Approval Authority
Test Results
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Qualification Protocol written by Project Team & Approval Authority
Qualification Protocol Report
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APPROVAL AUTHORITY
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Area Manager
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Cross-Functional Group designed to sign for that type of validation
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Cross-Functional Group designed to sign for that of validation Includes Quality & Technical Services, R&D, Process Engineering
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Cross-Functional Managerial Group designated for that type of validation
Includes Quality & Technical Services, R&D, Process Engineering
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The following is a schematic representation of the change control scope. The results of the criticality and complexity matrices leads to the appropriate change control or validation effort described in the previous table. The results are determined as follows:
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