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[DOCKET NO. 91N-0450] GUIDELINE FOR QUALITY ASSURANCE IN BLOOD ESTABLISHMENTS. July 11, For further information about this document, contact: - PDF
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1 [DOCKET NO. 91N-0450] GUIDELINE FOR QUALITY ASSURANCE IN BLOOD ESTABLISHMENTS July 11, 1995 For further information about this document, contact: Center for Biologics Evaluation and Research (HFM-635) Food and Drug Administration 1401 Rockville Pike Rockville, MD Submit written comments on this document to: Dockets Management Branch (HFA-305) Food and Drug Administration Rm Parklawn Dr. Rockville, MD Submit requests for single copies of this document to: Congressional and Consumer Affairs Branch (HFM-12) Food and Drug Administration 1401 Rockville Pike Rockville, MD FAX Comments and requests should be identified with the docket number found in brackets at the heading of this document.
2 TABLE OF CONTENTS PURPOSE... 1 SCOPE... 1 INTRODUCTION... 2 QUALITY CONTROL/ASSURANCE PROGRAM... 3 QUALITY ASSURANCE FUNCTION... 3 Reporting Responsibilities... 4 QUALITY CONTROL/ASSURANCE UNIT RESPONSIBILITIES... 5 Standard Operating Procedures (SOPs)... 5 Training and Education... 6 Competency Evaluation... 7 Proficiency Testing... 7 Validation... 8 Equipment... 8 Error/Accident Reports, Complaints, and Adverse Reactions... 8 Records Management... 9 Lot Release Procedures... 9 Quality Assurance Audits APPENDICES GLOSSARY REFERENCES Health and Human Services References General References... 34
3 QUALITY ASSURANCE IN BLOOD ESTABLISHMENTS PURPOSE The purpose of this guideline is to assist manufacturers of blood and blood components, including blood banks, transfusion services, and plasmapheresis centers, in developing a quality assurance (QA) program in their effort to be consistent with recognized principles of quality assurance and current good manufacturing practice (CGMP). SCOPE This guideline provides general information on procedures and practices and may be useful to blood establishments in developing and administering a QA program. Because the Food and Drug Administration (FDA) is in the process of revising 21 CFR 10.90(b), this document is not being issued under the authority of 21 CFR 10.90(b), and the document, although called a guideline, does not bind the agency and does not create or confer any rights, privileges, or benefits for or on any person. Blood establishments may follow the guideline or may choose to use alternative procedures not provided in the guideline. If a blood establishment chooses to use alternative procedures, the establishment may wish to discuss the matter further with the agency to prevent expenditure of resources on activities that may be unacceptable to the FDA. Blood and blood components applicable to the prevention, treatment, or cure of human diseases or injuries are biological products subject to regulation pursuant to Section 351 of the Public Health Service (PHS) Act [42 U.S.C. 262]. Similarly, blood and blood components intended for use in the diagnosis, cure, mitigation, treatment, or prevention of diseases in humans are drugs as defined in Section 201(g) of the Federal Food, Drug, and Cosmetic (FD&C) Act [21 U.S.C. 321(g)]. Section 501 (a)(2)(b) of the FD&C Act states, in part, that a drug shall be deemed to be adulterated if "the methods used in, or the facilities or controls used for, its manufacture, processing, packing, and holding do not conform to or are not operated or administered in conformity with current good manufacturing practice to assure that such drug meets the requirements" of the FD&C Act. Because blood and blood components are drugs under the FD&C Act, the Current Good Manufacturing Practice regulations in 21 CFR, Parts 210 and 211 are applicable. In addition, FDA has issued CGMP 1
4 regulations for blood and blood components in 21 CFR, Part 606. This guideline is intended to be used in conjunction with the applicable federal standards in 21 CFR, Parts 600 through 680 and Parts 210 and 211. Section provides that the regulations in Parts 210 through 226 and 600 through 680 are considered to supplement, not supersede, each other. Where it is impossible to comply with the applicable regulations in both Parts 210 through 226 and Parts 600 through 680, the regulations specifically applicable to the product shall apply and supersede the more general regulations. Some examples of 21 CFR, Parts 210 and 211 and Parts 600 through 680 supplementing each other are set forth in Appendix A. This guideline may be amended periodically as needed. Blood establishments should be aware that under the Clinical Laboratory Improvement Amendments of 1988 (CLIA), establishments performing laboratory testing, including blood banks, transfusion services, and plasmapheresis centers, must also comply with applicable regulations in 42 CFR, Part 493. These regulations, generally effective September 1, 1992, establish standards for laboratory personnel, quality control, proficiency testing, patient test management, and QA based on test complexity and patient risk factors. INTRODUCTION It is generally believed that the United States has one of the safest blood supplies in the world. This is due in large part to the development and implementation of standards for donor suitability and product quality. Since 1983, many significant developments have occurred including the implementation of new tests and donor suitability criteria. In addition, the FDA has intensified its oversight of blood establishments and has documented the release of unsuitable blood and blood components in a number of situations due to deficiencies from established standards. These findings may be related to several factors: (1) the increase in the number of tests performed (increased testing increases the opportunity for errors and contributes to the complexity of the operation), (2) the increasing use of complex advanced technology in testing procedures and equipment including computerized systems, (3) a shortage of appropriately trained health care and laboratory personnel, 2
5 and (4) the need for more sophisticated process and system control procedures in blood establishments, including procedures for training and supervising existing personnel. In a memorandum dated April 6, 1988, FDA's Center for Biologics Evaluation and Research (CBER) requested that blood establishments review procedures and employee training programs to determine the adequacy of safeguards to prevent the release of unsuitable blood products. CBER issued a memorandum on March 20, 1991, notifying blood establishments of the increasing number of product recalls due to errors and accidents in manufacturing. CBER described examples of the types of errors and accidents that have resulted in the release of unsuitable products. In addition, CBER reminded establishments of the reporting requirement for errors and accidents and the need for follow-up investigation. To ensure the continued safety of the nation's blood supply, it is essential that blood establishments implement effective control over manufacturing processes and systems. FDA believes that this can be accomplished by each blood establishment developing a well planned, written, and managed QA program designed to recognize and prevent the causes of recurrent deficiencies in blood establishment performance. The goals of QA are to significantly decrease errors, ensure the credibility of test results, implement effective manufacturing process and system controls, and ensure continued product safety and quality. QA includes measures to prevent, detect, investigate, assess, and correct errors. The emphasis is on preventing errors rather than detecting them retrospectively. Implementing a QA program requires a commitment of time and resources. The design and scope of a QA program depend on the size and complexity of manufacturing operations performed by the establishment. The potential public health consequences require that all establishments, regardless of size, invest in QA. QUALITY CONTROL/ASSURANCE PROGRAM A QA program is a system designed and implemented to ensure that manufacturing is consistently performed in such a way as to yield a product of consistent quality. QA is the sum of activities planned and performed to provide confidence that 3
6 all systems and their elements that influence the quality of the product are functioning as expected and relied upon. There are several dimensions to QA including quality control (QC) procedures and current good manufacturing practice. Adequate quality control procedures are an element of conformity with CGMP and include the routine on-line or in- process monitoring of manufacturing procedures [See 21 CFR (a), (a), (b)]. Other dimensions of QA relevant to the control of production include standards for personnel, facilities, procedures, equipment, testing, and recordkeeping activities. QUALITY ASSURANCE FUNCTION A quality control unit having the responsibility and authority to ensure product quality is required by 21 CFR (a). In the pharmaceutical industry, the group performing this function often has been titled the Quality Control Unit. With the evolution of the concept of QA during the past 20 years, the group responsible for oversight of all activities relating to product quality (including quality control) often has been titled the Quality Assurance Unit. Subsequently, in practice, the term quality control often has been considered by many as limited to describing the component of a QA program that includes the activities and controls used to determine the accuracy of the establishment's equipment and operations in manufacturing (i.e., on-line or in-process testing) and product release. Irrespective of the title of the person or persons performing QA duties, a quality assurance function should be established. Although the term "quality assurance" is not used in 21 CFR, Parts 210 and 211 and Parts 600 through 680, these regulations clearly require a program of activities to control the manufacturing process to prevent the release of unsuitable products. For purposes of clarity, this document uses the term "quality assurance" to describe the actions, planned and performed, to provide confidence that all systems and elements that influence the quality of the product are working as expected. The person or group of persons who perform this function will be referred to as the QC/QA Unit. The terms "quality control" and "quality assurance" will be defined as stated above and in the glossary. 4
7 The QC/QA Unit should coordinate, monitor, and facilitate all QA activities. The QC/QA Unit may include one or more individuals dedicated solely to QA functions or individuals who also perform other tasks in the establishment. In the latter situation, however, individuals should not have final oversight of their own work [See 21 CFR (c), ]. In a small firm, it may be feasible for one individual to function as the QC/QA Unit. That person has the responsibility for implementing controls and reviewing results of manufacturing to ensure that product quality standards are met. Reporting Responsibilities A QC/QA Unit should report to management or its designee. In licensed firms, this unit should report to the Responsible Head who is the individual designated in the establishment license application to represent the firm in its regulatory activities with CBER [See 21 CFR (a)] or his/her designee. In unlicensed firms, the QC/QA Unit should report to a "designated qualified person" [See 21 CFR (a)] or his/her designee. The Responsible Head or the designated qualified person is required to exercise control over the establishment in regard to all matters related to compliance with FDA requirements including the FD&C Act and the PHS Act, and should have the authority to implement corrective action when necessary. These individuals are responsible for ensuring corrective action has been taken. The Responsible Head or designated qualified person is also responsible for ensuring that personnel are appropriately assigned and trained to accomplish their duties [See 21 CFR , , ]. The QC/QA Unit reports independently from production to management. The QC/QA Unit should ensure that production personnel follow CGMP. When necessary, the QC/QA Unit should have the authority to stop production and/or release of product. QUALITY CONTROL/ASSURANCE UNIT RESPONSIBILITIES The responsibilities of a QC/QA Unit in blood establishments should include, but are not limited to, the following areas: Standard Operating Procedures (SOPs) [See 21 CFR , (e), ] 5
8 QA activities relevant to SOPs include: (1) Determining that SOPs exist for all manufacturing procedures including, but not limited to, testing, and that SOPs accurately describe and define the procedure, including a statement of what the procedure is intended to accomplish. The actual content of the SOPs may be the responsibility of the production units [See Federal Register, Volume 43, No. 190, Sept. 29, 1978, pp , 45032]. (2) Reviewing and ensuring written approval of all SOPs prior to implementation and confirming that SOPs comply with all applicable statutory and regulatory requirements. Additionally, prior to the implementation of each SOP, the QC/QA unit ensures that the following items are written and in place: (a) (b) (c) (d) (e) (f) (g) (h) (i) procedures to establish validation protocols to ensure that methods and processes accomplish their intended purpose; identification of personnel responsible for performing each procedure; procedures for training and certifying individuals identified in (b); responsibilities of supervisors for oversight of the performance of all procedures; methods for periodic proficiency testing; methods for periodic competency evaluation of the individuals performing each procedure; methods for evaluating the performance of each procedure during QA audits; designation of each procedure as a critical or noncritical control point (as defined in the glossary); and instructions for records maintenance consistent with requirements for recordkeeping. (3) Maintaining an index of all SOPs, a master copy, and an archive of obsolete SOPs. (4) Ensuring that the SOP content is reviewed to assess impact on other systems and their functions. 6
9 (5) Ensuring that each employee is provided with, and has ongoing access to, the necessary SOPs to perform assigned duties. (6) Ensuring that validation protocols are designed prospectively, performed and evaluated, and that written validation reports are prepared. Validation of a process already in use may be based upon accumulated production, testing, and control data. (7) Ensuring that modifications or changes in SOPs are appropriately documented including the rationale for the change. Ensuring that revised or new methods and processes are validated and do not create an adverse impact elsewhere in the system or operation. Changes in SOPs should be made in accordance with a written procedure and be formally approved before implementation. (8) Ensuring that SOPs for all QC/QA unit activities exist and define the QC/QA unit's responsibility for performing SOP review, approval, or authorization or, if appropriate, ensuring review, approval, or authorization has been performed. (9) Ensuring pertinent SOPs are promptly updated to reflect changes in manufacturer's directions for use and all SOPs and manufacturing records are reviewed at least annually. Training and Education The QC/QA Unit should assist in developing, reviewing, and ensuring the approval of training and educational programs for all personnel [See 21 CFR ]. Training should include the following programs: New employee orientation, CGMP training, SOP training, Technical training, Supervisory training, Managerial training, QA training, Computerized system training, and Continuing education and training. 7
10 The QC/QA Unit should be aware of factors that indicate a need for training or retraining. Information regarding the need for such training may be derived from management observations, proficiency test results, competency evaluations, technical changes, error/accident reports, complaints, QA audits, and problems discovered at critical control points identified in each system within the establishment's total operation. Thresholds for implementing retraining programs should be established. Competency Evaluation To ensure that all staff are trained and maintain their competency to perform all assigned tasks, the QC/QA Unit should implement a formal regular competency evaluation program. A competency evaluation program should evaluate theoretical and practical knowledge of procedures including, but not limited to, the following: (1) Direct observations of performance of routine and quality control procedures including, as applicable, donor suitability, sample handling, processing, testing, labeling, and instrument preventive maintenance; (2) Monitoring the recording and reporting of test results by reviewing work sheets, quality control records, preventive maintenance records, and other records and entries (both manual and automated); (3) Written tests to assess problem solving skills, knowledge of SOPs, and theory; and (4) Assessment of performance using internal blind specimens and external proficiency test specimens. Minimum acceptable scores, performance, and remedial measures to correct inadequate performance on competency evaluations should be documented and retained in personnel records. Evaluation summaries provide useful information to correct individual or group performance problems. Proficiency Testing Proficiency tests are commonly one part of the QA program for testing laboratories. In addition to the facility's standard review of proficiency test results, the QC/QA Unit should also review, evaluate, and monitor the proficiency testing program 8
11 to ensure the adequate evaluation of test methods and equipment and competency of personnel performing testing. Blood establishment proficiency testing procedures should ensure that proficiency samples are tested by all personnel normally performing routine testing, using routine test equipment, during routine test runs. Blood establishments should provide for proficiency testing of back-up or alternate test methods, e.g., manual procedures or "stat" tests. Procedures should ensure accurate, reliable, and prompt test results. Supervisors, management, and the QC/QA unit should review and evaluate proficiency test results. Additionally, the QC/QA Unit should analyze results for trends or patterns to identify specific problems. There should be a written plan for remedial action in the case of unsuccessful proficiency test performance. Other quality control procedures may be useful in monitoring laboratory performance. These include statistical reviews of unknown and control sample results, comparisons of initial and repeat test values, and results of the same test performed by different methods or at different sites. Validation The FDA has provided general guidance in its Guideline on General Principles of Process Validation (May, 1987) which should be referenced to determine the validation principles applicable to an individual establishment's systems and processes. The QC/QA unit should ensure that adequate validation procedures have been performed. Complaints, errors, accidents, and problems at critical control points should be reviewed to determine the need for revalidation or revision of validation procedures. Equipment Equipment installation qualification is performed to establish "confidence that process equipment and ancillary systems are capable of consistently operating within established limits and tolerances" [Guideline on General Principles of Process Validation (May, 1987)]. The QC/QA Unit should ensure that procedures are in place for equipment qualification, process validation, and revalidation after repairs to ensure the proper function of all equipment. Appropriate records of the 9
12 results of validation testing should be reviewed and maintained. There should be written procedures for equipment qualification, validation, maintenance, and monitoring. Additionally, there should be schedules for equipment monitoring, calibration, and maintenance sufficient to ensure that performance is according to specifications. Equipment monitoring procedures should include evaluation of consequences of malfunctioning or out-of-calibration equipment. Computer systems used in manufacturing are equipment subject to 21 CFR and Error/Accident Reports, Complaints, and Adverse Reactions The QA program should provide assurance that procedures are in place and exactly followed for the review, evaluation, investigation, and correction of manufacturing errors and accidents. There should also be a system to ensure timely reporting to CBER of errors and accidents that may affect the safety, purity, identity or quality of blood products [See 21 CFR ]. QA procedures should ensure that all complaints regarding product quality are investigated to determine whether the complaint is related to an error or accident in manufacturing. Investigative procedures should include provisions for review to determine whether the complaint represents an adverse reaction. Donor or recipient adverse reactions may be life-threatening, permanently disabling, or fatal. Procedures should be in place to ensure that donor and recipient adverse reactions are thoroughly investigated and completely documented. Fatalities must be reported to CBER in accordance with 21 CFR (b). The QC/QA Unit should ensure that product recalls and market withdrawals are handled according to established procedures and guidelines [See 21 CFR, Part 7]. Procedures should be in place to ensure transfusion reactions are investigated. A program should be in place to train patient care staff to recognize symptoms of adverse reactions so that appropriate intervention can be taken. Procedures should include review of manufacturing procedures when bacterial contamination of the product is suspected. Possible bacterial contamination should be reported to the blood collection facility. An essential element of QA is feedback into the QA system of knowledge acquired through investigations of complaints, 10
13 error/accident incidents, and adverse reactions. If there is no investigation of complaints, error/accidents, or adverse reactions, factors contributing to the problems cannot be identified and corrected. Errors or accidents in manufacturing may be identified either by employees in the course of routine activities or by supervisors during record review. The QC/QA Unit should assess all errors that occur during manufacturing, including those identified before products are released. The QC/QA Unit should receive copies of error/accident reports and ensure appropriate follow-up actions have been taken. There should be procedures for initiating and completing all corrective actions. Corrective actions may include system or process redesign, retraining, and procedural changes. Records Management The QC/QA Unit should approve or ensure approval of all recordkeeping systems (manual and automated). Electronic or computerized recordkeeping systems should be properly validated [See 21 CFR ]. QA procedures should be implemented to ensure that required records [See 21 CFR ] are reviewed as necessary to ensure the accurate and complete history of all work performed. Portions of the review may be performed at appropriate periods during or after blood collecting, processing, compatibility testing, and storing [See 21 CFR (c)]. Lot Release Procedures Each component, as defined in 21 CFR 606.3(c), (e.g., Red Blood Cells, Platelets, Plasma, or Cryoprecipitated AHF) prepared from a unit of whole blood represents one lot of product and bears a lot number, which is often the unit number assigned at the time of collection. QA procedures should be implemented to ensure that records are reviewed for accuracy, completeness, and compliance with established standards. A second person should review each significant step in each process associated with every component prior to release [See 21 CFR (c), (a)(7)&(8)]. QA procedures should be in place to ensure that any lot discrepancies or failure of a lot or unit to meet its specifications are thoroughly investigated. Labeling control procedures should be appropriate to the system and equipment. If automated labeling equipment retains information that could be erroneously printed during subsequent use, strict control procedures to prevent this 11
14 should be implemented [See 21 CFR ]. There should be written procedures designed and followed to ensure that correct labels, labeling, and packaging material are used for drug products [See 21 CFR ]. Blood and blood components are labeled at various stages in the manufacturing process. At collection, products may be labeled as to the type of product the facility anticipates manufacturing. Products may be labeled as to blood group and expiration date at a later point in the manufacturing process. Products may be converted from one product type to another (e.g., Fresh Frozen Plasma to Recovered Plasma, Whole Blood to Red Blood Cells) and subsequently relabeled. Relabeling of blood products due to conversion to another product must undergo the same control procedures and have the same records maintained as the initial labeling operation. At each stage in the manufacturing process where labeling occurs, there should be process controls that ensure correct labels have been applied. Prior to release, the completely labeled product should be reviewed. Control procedures for final label review should include review of applicable production records and a record of verification by a second individual to ensure products have been properly labeled, e.g., donor classification, blood group, expiration date, and product name. When proper control procedures for labeling are followed, labeling errors are minimized. Quality Assurance Audits A QA audit is one mechanism for evaluating the effectiveness of the total QA system. Comprehensive audits should be conducted periodically in accordance with written procedures [See 21 CFR (e)]. A comprehensive audit should consist of review of a statistically significant number of records. A focused audit may be necessary when quality problems have been identified, or to monitor, more effectively, a particularly critical area. However, isolated audits restricted to one area may not detect system-wide problems. The QC/QA Unit's written procedures for a focused audit should be flexible enough to allow for additional audits without requiring changes in SOPs. Audit procedures will vary in complexity depending on the size of the establishment and the specific processes under review. Individuals conducting audits should possess sufficient knowledge, training, and experience to identify problems in 12
15 the specific processes under review. The auditor or audit team should not be responsible for performing the procedures being audited. In situations in which an external audit program is used, the QC/QA unit is responsible for assuring that the audit meets the needs of the establishment and is consistent with 21 CFR (e). The annual review required by 21 CFR (e) is not viewed as a QA audit, and records of these reviews must be available during FDA inspections. There should be a written report documenting audit procedures and results. Procedures should include a plan for the Responsible Head or designated qualified person and other appropriate responsible officials to review and evaluate the results of the audit. The purpose of the review and evaluation is to ensure that responsible individuals are aware of problems, and corrective action is implemented. Audit reports should be retained for a period consistent with product record retention requirements. QA audits should be structured using a systems approach. Major systems of a blood manufacturing operation are identified in Tables 1-8, Appendix B. The systems which may comprise blood establishment operations and that should be audited should include, at a minimum, the following: Quality Control/Assurance; Donor Suitability; Blood Collection; Component Manufacturing; Product Testing; Storage and Distribution; Lot Release; and Computer. Each system may function independently or collectively with other systems. The critical control points in each system refer to areas that may affect the safety and quality of the product if key elements are not performed or functioning correctly. The key elements are individual steps in each critical control point. QA audits should evaluate critical control points and key elements in each system. Examples of critical control points and associated key elements are included in Tables 1-8, Appendix B. Each establishment should customize its audit for its own systems. 13
16 APPENDICES 14
17 Appendix A. Examples of 21 CFR, Parts 210 through 211 and Parts 600 through 680 Supplementing Each Other. The CGMP regulations for drugs are useful in ensuring the quality of blood and blood products, and implementing these regulations is both feasible and practical. The CGMP regulations in 21 CFR 211 are general and suitable for all finished pharmaceuticals, and flexible to permit innovation. These regulations provide some flexibility to manufacturers to select the methods and processes most suitable for the products and operations of the individual firms. Notwithstanding such flexibility, manufacturers must, of course, create and implement procedures that are sufficient to accomplish all objectives of the CGMP regulations. In those few cases where precise procedures are set forth in the CGMP regulations, individuals believing that alternative mechanisms may also be acceptable are invited to request approval to use an alternative procedure pursuant to 21 CFR The term "lot" is defined for biological products in 21 CFR 600.3(x). This same term is also defined in 21 CFR 210.3(b)(10). The term "batch" is defined in 21 CFR 210.3(b)(2) as a specific quantity of a drug or other material that is intended to have uniform character and quality, within specified limits, and is produced according to a single manufacturing order during the same cycle of manufacture. For purposes of good manufacturing practice, a unit of whole blood or each of its components collected for transfusion or further manufacturing is both a lot and a batch. Testing for a single unit of blood may be performed as part of a run consisting of testing many other units of blood at the same time. In situations where testing (or other manufacturing) records include the results of more than one unit in a single record, signatures need only be written on the record as a whole rather than next to the results of each unit. The regulations in 21 CFR, Parts 210 through 226, and 600 through 680 are considered to supplement, not supersede, each other, unless the regulations explicitly provide otherwise. In the event that it is impossible to comply with all applicable regulations in both 21 CFR, Parts 600 through 680 and Parts 200 through 211, the regulations specifically applicable to the drug in question shall supersede the more general regulations. The following charts provide examples of 21 CFR, Part 211 and Parts 600 through 680 supplementing each other. The highlighted text in 21 CFR 211, CGMP 15
18 for Finished Pharmaceutical, identifies additional standards of CGMP that are also applicable to blood and blood components. 16
19 CURRENT GOOD MANUFACTURING PRACTICE SPECIFIC FOR BLOOD AND BLOOD COMPONENTS The biologic regulations describe requirements for record review, product quality control, laboratory controls, equipment controls, and SOPs for quality control, but do not explicitly refer to a QC/QA Unit. The Part 211 CGMPs specify that a person or group of persons will be responsible for performing these functions [21 CFR ] CURRENT GOOD MANUFACTURING PRACTICE FOR FINISHED PHARMACEUTICAL (INCLUDES BLOOD AND BLOOD COMPONENTS) (a) There shall be a quality control unit that shall have the responsibility and authority to approve or reject all components, drug product containers, closures, in-process material, packaging material, labeling, and drug products, and the authority to review production records to assure that no errors have occurred or, if errors have occurred, that they have been fully investigated. (c) The quality control unit shall have the responsibility for approving or rejecting all procedures or specifications impacting on the identity, strength, quality, and purity of the drug product. (d) The responsibilities and procedures applicable to the quality control unit shall be in writing; such written procedures shall be followed. Comprehensive audit record review may consist of review of a sample of records that are representative of product production. A review of every complaint, recall, and product failure must be performed (e) Written records required by this part shall be maintained so that data therein can be used for evaluating, at least annually, the quality standards of each drug product to determine the need for changes in drug product specifications or manufacturing or control procedures. Written procedures shall be established and followed for such evaluations and shall include provisions for: (1) A review of every batch, whether approved or rejected, and, where applicable, records associated with the batch. (2) A review of complaints, recalls, returned or salvaged drug products, and investigations conducted under for each drug product (b) Written standard operating procedures (a) There shall be written procedures for production and shall be maintained and shall include process control designed to assure that the drug products all steps to be followed in the have the identity, strength, quality, and purity they purport collection, processing, compatibility or are represented to possess. Such procedures shall include testing, storage and distribution of all requirements in this subpart. These written procedures, blood and blood components for including any changes, shall be drafted, reviewed, and homologous transfusion, autologous approved by the appropriate organizational units and reviewed transfusion and further manufacturing and approved by the quality control unit. purposes. Such procedures shall be (b) Written production and process control procedures shall available to the personnel for use in be followed in the execution of the various production and the areas where the procedures are process control functions and shall be documented at the time performed unless this is impractical. of performance. Any deviation from the written procedure should be recorded and justified. 17
20 CURRENT GOOD MANUFACTURING PRACTICE SPECIFIC FOR BLOOD AND BLOOD COMPONENTS (c) All records pertinent to the lot or unit maintained pursuant to these regulations (i.e., Parts 600 through 680) shall be reviewed before the release or distribution of a lot or unit of final product. The review or portions of the review may be performed at appropriate periods during or after blood collecting, processing, compatibility testing and storing. A thorough investigation, including the conclusions and follow-up, of any unexplained discrepancy or the failure of a lot or unit to meet any of its specifications shall be made and recorded. Record review specified in may be performed by the QC/QA unit which is comprised of one or more individuals dedicated solely to QA functions or individuals who also perform other tasks in the establishment. In the latter situation, however, individuals should not have final oversight of their own work. CURRENT GOOD MANUFACTURING PRACTICE FOR FINISHED PHARMACEUTICAL (INCLUDES BLOOD AND BLOOD COMPONENTS) All drug product production and control records, including those for packaging and labeling, shall be reviewed by the quality control unit to determine compliance with all established, approved written procedures before a batch is released or distributed. Any unexplained discrepancy... or the failure of a batch or any of its components to meet any of its specifications shall be thoroughly investigated, whether or not the batch has already been distributed. The investigation shall extend to other batches of the same drug product and other drug products that may have been associated with the specific failure or discrepancy. A written record of the investigation shall be made and shall include the conclusions and follow-up (a) Laboratory records shall include complete data derived from all tests necessary to assure compliance with established specifications and standards including examinations and assays, as follows: (7) The initials or signature of the person who performs each test and the date(s) the tests were performed. (8) The initials or signature of a second person showing that the original records have been reviewed for accuracy, completeness, and compliance with established standards. There should be SOPs describing product release procedures in emergency situations. Documentation of review of suitability of results included in in-process and laboratory testing records may consist of the signatures of the individual performing the procedure and the individual reviewing the records on the record as a whole rather than next to the results that pertain to the individual unit. Appropriate SOPs should be in place identifying individuals responsible for review and the criteria for review. 18
21 CURRENT GOOD MANUFACTURING PRACTICE SPECIFIC FOR BLOOD AND BLOOD COMPONENTS CURRENT GOOD MANUFACTURING PRACTICE FOR FINISHED PHARMACEUTICAL (INCLUDES BLOOD AND BLOOD COMPONENTS) (a) Written procedures shall be established and followed prescribing a system for reprocessing batches that do not conform to standards or specifications and the steps to be taken to insure that the reprocessed batches will conform with all established standards, specifications, and characteristics. (b) Reprocessing shall not be performed without the review and approval of the quality control unit. 19
22 CURRENT GOOD MANUFACTURING PRACTICE SPECIFIC FOR BLOOD AND BLOOD COMPONENTS CURRENT GOOD MANUFACTURING PRACTICE FOR FINISHED PHARMACEUTICALS (INCLUDES BLOOD AND BLOOD COMPONENTS) (b) The personnel responsible for the collection, processing, compatibility testing, storage or distribution of blood or blood components shall be adequate in number, educational background, training and experience, including professional training as necessary, or combination thereof, to assure competent performance of their assigned functions, and to ensure that the final product has the safety, purity, potency, identity and effectiveness it purports or is represented to possess. All personnel shall have capabilities commensurate with their assigned functions, a thorough understanding of the procedures or control operations they perform, the necessary training or experience, and adequate information concerning the application of pertinent functions of this part to their respective functions (a) Each person engaged in the manufacture, processing, packing or holding shall have education, training, and experience, or any combination thereof, to enable that person to perform the assigned functions. Training shall be in the particular operations that the employee performs and in current good manufacturing practice (including the current good manufacturing practice regulations in this chapter and written procedures required by these regulations) as they relate to the employee's functions. Training in current good manufacturing practice shall be conducted by qualified individuals on a continuing basis and with sufficient frequency to assure that employees remain familiar with CGMP requirements applicable to them. (b) Each person responsible for supervising the manufacture, processing, packing, or holding of a drug product shall have the education, training, and experience or any combination thereof, to perform assigned functions in such a manner as to provide assurance that the drug product has the safety, identity, strength, quality, and purity that it purports or is represented to possess. (c) There shall be an adequate number of qualified personnel to perform and supervise the manufacture, processing, packing or holding of each drug product. 20
23 CURRENT GOOD MANUFACTURING PRACTICE SPECIFIC FOR BLOOD AND BLOOD COMPONENTS CURRENT GOOD MANUFACTURING PRACTICE FOR FINISHED PHARMACEUTICALS (INCLUDES BLOOD AND BLOOD COMPONENTS) (c) Persons whose presence can (a) Personnel engaged in the manufacture, processing, packing, or adversely affect the safety and holding of a drug product shall wear clean clothing appropriate for purity of the products shall be the duties they perform. Protective apparel, such as head, face, and excluded from areas where the arm covering, shall be worn as necessary to protect drug products from collection, processing, contamination. compatibility testing, storage (b) Personnel shall practice good sanitation and health habits. or distribution of blood or (c) Only personnel authorized by supervisory personnel shall enter blood components is conducted. those areas of the buildings and facilities designated as limited In the Federal Register [40 FR access Nov. 18, 1975], the (d) Any person shown at any time (either by medical examination or Commissioner stated that the supervisory observation) to have apparent illness or open lesions that intent of this regulation is to may adversely affect the safety or quality of drug products shall be also exclude from the excluded from direct contact with components, drug products processing area persons who may containers, closures, in-process materials, and drug products until distract the attention of the the condition is corrected or determined by competent medical personnel from the performance personnel not to jeopardize the safety or quality of drug products. of their duties and persons who All personnel shall be instructed to report to supervisory personnel by their very presence in the any health conditions that may have an adverse effect on drug processing area are capable of products. affecting the safety and purity of the product (e.g., persons moving from testing areas to the processing area without taking the necessary precautions. The role of the Responsible Head in ensuring that personnel are appropriately trained and qualified for their duties is described in and (b) describes requirements for adequate ventilation describes ventilation control procedures in more detail Consultants advising on the manufacture, processing, packing, or holding of drug products shall have sufficient education, training, and experience, or any combination thereof, to advise on the subject for which they are retained. Records shall be maintained stating the name, address, and qualifications of any consultants and the type of service they provide (b) Equipment for adequate control over air pressure, micro-organisms, dust, humidity and temperature shall be provided when appropriate for the manufacture, processing, packing, or holding of a drug product. (c) Air filtration systems, including prefilters and particulate matter air filters, shall be used when appropriate on air supplies to production areas. If air is recirculated to production areas, measures shall be taken to control recirculation of dust from production. In areas where air contamination occurs during production, there shall be adequate exhaust systems or other systems adequate to control contaminants. 21
24 CURRENT GOOD MANUFACTURING PRACTICE SPECIFIC FOR BLOOD AND BLOOD COMPONENTS CURRENT GOOD MANUFACTURING PRACTICE FOR FINISHED PHARMACEUTICALS (INCLUDES BLOOD AND BLOOD COMPONENTS) (a) Potable water shall be supplied under continuous positive pressure in a plumbing system free of defects that could contribute contamination to any drug product... (b) Drains shall be of adequate size and, where connected directly to a sewer, shall be provided with an air break or other mechanical device to prevent back-siphonage. 22
25 CURRENT GOOD MANUFACTURING PRACTICE SPECIFIC FOR BLOOD AND BLOOD COMPONENTS CURRENT GOOD MANUFACTURING PRACTICE FOR FINISHED PHARMACEUTICALS (INCLUDES BLOOD AND BLOOD COMPONENTS) 21 CFR (c) describes adequate, clean, and Adequate facilities shall be provided, including hot and cold water, convenient hand washing soap or detergent, air dryers or single service towels, and clean facilities for personnel. toilet facilities easily accessible to working areas (a) Automatic, mechanical, or electronic equipment or other types of equipment including computers, or related systems that will perform a function satisfactorily, may be used in the manufacture, processing, packing, and holding of a drug product. If such equipment is so used, it shall be calibrated, inspected, or checked according to a written program designed to assure proper performance. Written records of those calibration checks and inspections shall be maintained. (b) Appropriate controls shall be exercised over computer or related systems to assure that changes in master production records or other records are instituted only by authorized personnel. Input to and output from the computer or related system of formulas or other records or data shall be checked for accuracy. The degree and frequency of input/output verification shall be based on the complexity and reliability of the computer or related system. A backup file of data entered into the system shall be maintained except where certain data, such as calculations performed in connection with laboratory analysis, are eliminated by computerization or other automated processes. Hard copy or alternative systems, such as duplicates, tapes, microfilm designed to assure that backup data are exact and complete and that it is secure from alteration, inadvertent erasures, or loss shall be maintained (d) Provide safe and sanitary (a) Any building used in the manufacture, processing, packing, or disposal for the following: holding of a drug product shall be maintained in a clean and sanitary (1) Trash and items used during condition. Any such building shall be free of infestation by rodents, the collection, processing and birds,insects and other vermin (other than laboratory animals). Trash compatibility testing of blood and organic waste matter shall be held and disposed of in a timely and and blood products. sanitary manner. (2) Blood and blood components not suitable for use or distribution. 23
26 CURRENT GOOD MANUFACTURING PRACTICE SPECIFIC FOR BLOOD AND BLOOD COMPONENTS CURRENT GOOD MANUFACTURING PRACTICE FOR FINISHED PHARMACEUTICALS (INCLUDES BLOOD AND BLOOD COMPONENTS) (a) Equipment used in the collection, processing, compatibility testing, storage and distribution of blood and blood components shall be maintained in a clean and orderly manner and located so as to facilitate cleaning and maintenance. The equipment shall be observed, standardized and calibrated on a regularly scheduled basis as prescribed in the SOP and shall perform in the manner for which it was designed so as to assure compliance with the official requirements prescribed in this chapter for blood and blood products (b)(15) requires that SOPs include schedules and procedures for equipment maintenance and calibration (b) Written procedures shall be established and followed for cleaning and maintenance of equipment, including utensils, used in the manufacture, processing, packing, or holding of a drug product. These procedures shall include, but are not necessarily limited to, the following: (1) Assignment of responsibility for cleaning and maintaining equipment; (2) Maintenance and cleaning schedules, including, where appropriate, sanitizing schedules; (3) A description in sufficient detail of the methods, equipment, and materials used in cleaning and maintenance operations, and the methods of disassembling equipment as necessary to assure proper cleaning and maintenance;... (5) Protection of clean equipment from contamination prior to use; (6) Inspection of equipment for cleanliness immediately before use. (c) Records shall be kept of maintenance, cleaning, sanitizing, and inspection as specified in and (b) Major equipment shall be identified by a distinctive identification number or code that shall be recorded in the batch production record to show specific equipment used in the manufacture of each batch of a drug product. In cases where only one particular type of equipment exists in a manufacturing facility, the name of the equipment may be used in lieu of a distinctive number or code. 24
27 CURRENT GOOD MANUFACTURING PRACTICE SPECIFIC FOR BLOOD AND BLOOD COMPONENTS CURRENT GOOD MANUFACTURING PRACTICE FOR FINISHED PHARMACEUTICALS (INCLUDES BLOOD AND BLOOD COMPONENTS) (b)(16) requires that written SOPs include labeling procedures and safeguards to avoid labeling mixups (b) The labeling operation shall include the following controls: (1) Labels shall be held upon receipt, pending review and proofing against an approved final copy, to ensure accuracy regarding identity, content, and conformity with the approved copy (a) There shall be written procedures describing in sufficient detail the receipt, identification, storage, handling, sampling, examination, and/or testing of labeling and packaging materials; such written procedures shall be followed. Labeling and packaging materials shall be representatively sampled, and examined or tested upon receipt and before use in packaging or labeling of a drug product. (b) Any labeling or packaging materials meeting appropriate written specifications may be approved and released for use. Any labeling or packaging that does not meet such specifications shall be rejected to prevent their use in operations for which they are unsuitable. (c) Records shall be maintained for each shipment received of each different labeling and packaging material indicating receipt, examination or testing and whether accepted or not... 25