What is GMP?
Good Manufacturing Practice (GMP) is a system for ensuring
that products are consistently produced and controlled according to quality
standards.
Good Manufacturing Practices (GMP)
are a set of guidelines that ensure the quality and safety of pharmaceutical
products. These practices are designed to minimize risks involved in production
and distribution, ensuring that products are consistently produced and
controlled to quality standards.
According to WHO (World Health Organization)
“Good Manufacturing Practices (GMP,
also referred to as 'cGMP' or 'current Good Manufacturing Practice') is the
aspect of quality assurance that ensures that medicinal products are
consistently produced and controlled to the quality standards appropriate to
their intended use and as required by the product specification.”
WHO defines GMP?
“Good manufacturing practice (GMP)
is that part of a quality management system to ensure that products are
consistently produced and controlled to the quality standards appropriate to
their intended use and as required by the marketing authorization.”
History and background of GMP in the pharmaceutical industry
As responses to tragic circumstances and to prevent future tragedies:
·
Use of Diethylene Glycol as solvent in sulfanilamide
(anti-infective) in the 1937s. 107 people died. (The-Sulfanilamide-Disaster)
·
Federal Food, Drug and Cosmetic Act (1938)
· Sulfathiazole tablets contaminated with Phenobarbital (sedative) in 1941. 300 people were killed.(Sulfathiazole Disaster)
· Sleeping pill Thalidomide caused serious deformities in developing fetuses in the 1960s in Europe (about 10,000 estimated cases).( Thalidomide scandal)
1962: Kefauver-Harris Amendments to the FD&C Act:
· FDA given authority to establish GMPs
· Failure to follow GMP = Drug Adulteration
Ø Late 1960‘s through 1970‘s contaminated IVs produced
· Validation required for sterile products, then all drug products
· 1981: Tylenol package tampering – pills were laced with cyanide, 7 people died
è Tamper-resistant packaging requirements for OTC drugs
· In 1963, FDA in USA prepared the guide-lines for GMP.
· In 1975, WHO issued the guide-lines for GMP
· In 1979, cGMP guidelines were prevailed.
Different GMP Guideline
GMP guidelines are named in different ways in different countries based on WHO-GMP and US FDA guideline.
· USFDA = United States Food & Drug Administration
· MHRA = Medicine and Healthcare Products Regulatory Agency- UK
· PMDA = Pharmaceuticals and Medical Devices Agency
· TGA = Therapeutic Good Administration- Australia
· KFDA = Korea Food and Drug Administration-Korea.
· MCC = Medicine Control Council -South Africa
· ANVISA = Agencia Nacional de Vigilancia Sanitaria-Brazil.
· EMEA = European Medicines Agency.
· TPD = Therapeutic Product Directorate—Canada.
· ICH = International Conference on Harmonization.
· PIC = Pharmaceutical Inspection Convention
· PICS =Pharmaceutical Inspection Co-operation Scheme
The Importance of GMP in the Pharmaceutical Industry
GMP is essential for:
· Ensuring product safety and efficacy.
· Protecting consumers from contaminated or defective products.
· Maintaining compliance with regulatory authorities.
· Enhancing the reputation of pharmaceutical companies.
Key points about the
importance of GMP in pharmaceuticals:
Patient Safety:
The primary goal of GMP is to
minimize risks to patients by guaranteeing that medications are produced
consistently with the correct specifications, preventing potential
contamination, potency variations, and other issues that could compromise
efficacy or safety.
Regulatory Compliance:
GMP serves as a regulatory
framework established by authorities like the FDA, meaning pharmaceutical
companies must comply with these standards to legally market their
products.
Quality Assurance:
GMP mandates comprehensive quality
control measures throughout the manufacturing process, including testing of raw
materials, in-process checks, and final product testing, ensuring consistent
quality across all batches.
Documentation and
Traceability:
GMP requires detailed documentation
of all manufacturing steps, including batch records, standard operating
procedures (SOPs), and quality control data, enabling thorough traceability of
products in case of recalls.
Manufacturing
Environment:
GMP specifies strict requirements
for the manufacturing facility, equipment, and personnel hygiene to minimize
the risk of contamination during production.
Process Validation:
Critical manufacturing steps must
be validated to ensure their consistency and reliability, further enhancing
product quality.
Industry Reputation:
Adherence to GMP standards builds
trust among consumers and healthcare professionals, contributing to a positive
industry reputation.
Overall, GMP plays a vital role in
safeguarding public health by ensuring that pharmaceutical products are
manufactured according to the highest quality standards, minimizing risks
associated with medication use, and upholding the integrity of the
pharmaceutical industry.
What are the 10 golden rules?
The 10 golden rules of GMP
discussed in this Whitepaper are:
Golden Rule # 1 |
Get the facility design right from
the start |
Golden Rule # 2 |
Validate processes |
Golden Rule # 3 |
Write good procedures and follow
them |
Golden Rule # 4 |
Identify who does what |
Golden Rule # 5 |
Keep good records |
Golden Rule # 6 |
Trains and develop staff |
Golden Rule # 7 |
Practice good hygiene |
Golden Rule # 8 |
Maintain facilities and equipment |
Golden Rule # 9 |
Build quality into the whole product
lifecycle |
Golden Rule #
10 |
Perform regular audits |
In general, there are 10 golden rules that apply in order to fulfill the GMP requirements.
Ten
basic Rules of GMP
- Be sure you have the correct written instructions
before any job is started.
- Always follow those instructions EXACTLY with no
“cutting corners”.
- Ensure that correct materials are being used.
- Ensure that correct equipment is being used and that
it is clean.
- Prevent contamination and mix up.
- Always guard against labeling errors.
- Always work accurately and precisely
- Keep things (including yourself) clean and tidy.
- Always be
on the lookout for mistakes, errors and bad practices and report them
immediately.
- Make clear, accurate records of what has been done,
and the checks carried out.
WHO good manufacturing practices for pharmaceutical products: main principles
Quality management in the medicines industry: philosophy and essential
elements-
1.
Pharmaceutical
Quality System
ii)
Product
Quality Review
2.
Good manufacturing
practices for pharmaceutical products
3.
Sanitation and
hygiene
4.
Qualification and
validation
5.
Complaints
6.
Product recalls
7.
Contract production,
analysis and other activities
8.
Self-inspection,
quality audits and suppliers’ audits and approval
9.
Personnel
10. Training
11. Personal hygiene
12. Premises
13. Equipment
14. Materials
15. Documentation
16. Good practices in production
17. Good practices in quality control
1. Pharmaceutical Quality System
A pharmaceutical quality
system (PQS) is a framework of procedures and controls that ensures
pharmaceutical products meet quality standards throughout their
lifecycle:
- Quality: Ensures the
desired product quality is met
- Process performance: Ensures suitable process
performance is achieved
- Controls: Ensures the set of controls
are appropriate
- Improvement: Identifies and evaluates
improvement opportunities
- Knowledge: Continually expands the body of knowledge
A PQS covers all aspects of
production, from product development through manufacturing, distribution, and
product discontinuation. It's based on guidelines from the International
Council for Harmonisation of Technical Requirements for Pharmaceuticals for
Human Use (ICH). A PQS also builds on Good Manufacturing Practices
(GMPs).
A PQS includes processes
such as:
Risk management, Equipment
calibration, Continuous improvement, Document management, Change control,
Training management, Audit management, CAPA management, and Deviation
management.
A PQS should reflect the
specific needs of the pharmaceutical company and applicable regulatory
requirements. It can help pharmaceutical companies: mitigate risks,
improve customer satisfaction, and streamline quality processes.
2.
Good manufacturing practices for pharmaceutical products
Good Manufacturing Practices (GMP) are a set of quality assurance standards that ensure pharmaceutical products are consistently produced and controlled to meet quality standards. GMPs are designed to minimize risks that can't be eliminated through testing the final product.
3.
Sanitation and hygiene
Sanitation and hygiene
are important for preventing disease and promoting human well-being:
·
Sanitation
Involves the safe disposal of human waste
and the provision of facilities and services for that. Sanitation
includes:
o
Wastewater disposal
o
Excreta removal
o
Water sanitation, such as treating drinking water
o
Handling of garbage and cow dung
o
Home sanitation and food hygiene
·
Hygiene
Involves personal hygiene practices, such as
handwashing, which removes infectious agents from hands and prevents the spread
of disease
Sanitation systems, such
as toilets and latrines, promote health by:
- Preventing disease by avoiding
contact with pathogens or parasites contained in excreta
- Allowing people to dispose of their waste properly
4.
Qualification and validation
Qualification and validation
are processes that ensure the safety and quality of products, especially
in the pharmaceutical industry. Qualification is the process of proving
that equipment or systems are installed correctly, meet design specifications,
and work as expected. Validation is the process of proving that a process,
procedure, or method consistently produces a desired result.
Here are some key
differences between qualification and validation:
·
Focus
Qualification focuses on equipment and
facilities, while validation focuses on processes and methods.
·
Relationship
Qualification is the first step in
validation, and processes must be validated on qualified equipment.
·
Scope
Qualification only applies to equipment that
directly or indirectly impacts product quality and patient
safety. Validation applies to processes and procedures that affect product
quality and patient safety.
·
Examples
Qualifying an autoclave is an example of
qualification, while validating a sterilization process is an example of
validation.
5.
Complaints
In the pharmaceutical industry,
complaints typically refer to issues related to the quality, efficacy, or
safety of a drug product, including adverse reactions experienced by patients,
problems with packaging or labeling, lack of effectiveness, and manufacturing
defects, all of which can be reported by consumers, healthcare professionals,
or distributors.
Common
types of complaints in the pharmaceutical industry:
·
Adverse
drug reactions (ADRs):
Unexpected or harmful side effects
experienced by a patient after taking a medication, ranging from mild to severe
or even life-threatening.
·
Product
quality issues:
Complaints about the physical appearance of
a drug (color, texture, etc.), issues with dosage forms (tablets breaking
easily), or problems with packaging (tamper-evident seals not intact).
·
Labeling
errors:
Incorrect information on the drug label,
such as dosage instructions, warnings, or active ingredients.
·
Manufacturing
defects:
Issues arising from the manufacturing
process, like contamination, incorrect potency, or improper storage conditions.
·
Lack
of efficacy:
Complaints that a medication is not
providing the expected therapeutic effect.
·
Patient
access issues:
Complaints related to difficulties in
obtaining a prescription medication, including insurance coverage limitations
or high cost.
·
Complaints
regarding sales practices:
Concerns about aggressive marketing tactics or misleading information provided by pharmaceutical sales representatives.
How
complaints are handled:
·
Reporting
system:
Pharmaceutical companies typically have a robust
system for collecting and investigating complaints, including dedicated contact
information for healthcare professionals and patients.
·
Complaint
investigation:
Once a complaint is received, a thorough
investigation is conducted to determine the root cause and take appropriate
corrective actions.
·
Regulatory
reporting:
Serious complaints, especially those related
to adverse drug reactions, must be reported to regulatory agencies like the
FDA.
·
Quality
assurance measures:
Companies implement quality assurance processes to prevent future complaints by monitoring production, identifying potential issues, and taking corrective actions.
6.
Product recalls
Pharmaceutical products
may be recalled for a variety of reasons, including:
- Complaints or reports
from manufacturers, wholesalers, retailers, hospitals, research
institutes, medical professionals, dentists, or patients
- Analysis and testing of samples by manufacturers or the Department of Health
The Food and Drug Administration
(FDA) enforces quality and safety standards for drug manufacturers and
pharmacies. While most recalls are initiated voluntarily by the
manufacturer, the FDA can also request or mandate a recall.
Some best practices for
handling a pharmaceutical product recall include:
·
Establish
a recall team
Include representatives from quality
assurance, regulatory affairs, legal, and communications
·
Develop
a recall plan
Outline procedures for identifying,
quarantining, and disposing of recalled products
·
Implement
a tracking system
Monitor the recall process from start to
finish
·
Communicate
effectively
Provide clear and timely information to
regulatory authorities, customers, and the public
·
Conduct
a root cause analysis
Determine the underlying cause of the issue and implement corrective and preventive actions
7.
Contract production, analysis and other activities
In the pharmaceutical industry, "contract production, analysis, and other activities" refers to the practice where a pharmaceutical company outsources specific parts of its drug manufacturing process, like raw material / Finished Goods production, formulation, packaging, or quality testing, to another company ("contract manufacturer") who specializes in those areas, instead of performing all steps in-house; essentially, paying another company to produce a part of their drug product according to their specifications and quality standards.
8.
Self-inspection, quality audits and suppliers’ audits and approval
"Self-inspection, quality audits, and suppliers' audits and approval" refers to a
comprehensive quality assurance system where a company regularly examines its
own manufacturing processes ("self-inspection"), conducts internal
assessments of quality systems ("quality audits"), and evaluates the
quality of materials and processes from their suppliers ("suppliers'
audits and approval") to ensure the consistent production of safe and
effective medications, all adhering to Good Manufacturing Practice (GMP)
standards.
Key
aspects of this system:
·
Self-inspection:
o
Performed by internal teams within the company, reviewing
their own operations against established GMP guidelines.
o
Aims to identify potential quality issues, non-compliance,
and areas for improvement within the manufacturing process.
o Should be documented thoroughly, with corrective actions implemented based on findings.
·
Quality
audits:
o
More rigorous evaluations conducted by a dedicated quality
assurance team, potentially including independent auditors.
o
Covers all aspects of the quality management system,
including documentation, production processes, and quality control
procedures.
o
Provides a comprehensive assessment of compliance and
identifies significant quality risks.
·
Suppliers'
audits and approval:
o
Assessing the quality systems of raw material suppliers to
ensure they meet the required standards for pharmaceutical production.
o
Includes on-site inspections of supplier facilities,
review of their quality documentation, and evaluation of their manufacturing
processes.
o Only approved suppliers whose quality meets the company's standards are used for sourcing materials.
Importance
of this system:
·
Patient
safety:
By ensuring consistent quality throughout
the manufacturing process, including raw materials, it protects patients from potential
harm caused by substandard medications.
·
Regulatory
compliance:
Adherence to GMP guidelines is crucial for
meeting regulatory requirements and obtaining market authorization for
pharmaceutical products.
·
Continuous
improvement:
Regularly identifying and addressing quality issues through self-inspections and audits allows for ongoing process refinement and quality enhancement.
9. Personnel
10.
Training
Training is crucial in
the pharmaceutical industry because it ensures compliance with strict
regulations, maintains high product quality, safeguards employee and patient
safety, promotes efficiency, and enables continuous innovation by keeping professionals
updated with the latest advancements in the field, ultimately impacting the
overall quality and reputation of a pharmaceutical company; essentially,
well-trained employees are essential for producing safe and effective
medications while adhering to industry standards.
Key reasons why training is important in the pharmaceutical
industry:
·
Compliance
with regulations:
The
pharmaceutical industry is heavily regulated, and proper training ensures
employees understand and follow all necessary guidelines to avoid regulatory
violations.
·
Quality
control:
Training
equips employees with the knowledge and skills to consistently maintain high
quality standards throughout the drug development and manufacturing
process.
·
Patient
safety:
By understanding
proper procedures and handling protocols, trained staff can minimize errors and
potential risks to patients.
·
Employee
safety:
Training on
handling hazardous materials and equipment is vital to protect employees from
workplace accidents.
·
Efficiency
and productivity:
Well-trained
employees can perform their tasks more effectively, leading to increased
productivity and streamlined operations.
·
Innovation
and adaptability:
Continuous
training allows employees to stay abreast of emerging technologies and
scientific advancements, fostering a culture of innovation within the
company.
·
Risk
management:
Trained
employees are better equipped to identify and mitigate potential risks
throughout the drug development process.
·
Professional
development:
Training
opportunities contribute to employee growth and career advancement.
·
Customer
satisfaction:
Properly
trained customer service representatives can provide accurate information and
support to customers, enhancing satisfaction levels.
Key aspects of pharmaceutical training:
·
Good
Manufacturing Practices (GMP):
Understanding
and adhering to GMP guidelines is essential for ensuring consistent product
quality.
·
Standard
Operating Procedures (SOPs):
Training on
SOPs ensures employees follow established protocols for all tasks.
·
Quality
Assurance (QA) and Quality Control (QC):
Training in
QA and QC procedures helps to monitor and maintain product quality throughout
the production process.
·
Regulatory
updates:
Continuous training to stay updated with changes in regulatory requirements
11.
Personal hygiene
Personal hygiene in the
pharmaceutical industry is important to prevent contamination and maintain a
clean environment:
- Wash hands: Wash hands with soap and
water before entering the production unit or handling materials.
- Wear PPE: Wear appropriate personal
protective equipment (PPE), such as gloves, head caps, shoes, or
fully-sanitized body coverings.
- Avoid contact: Avoid contact with others
and products if you have a contagious disease.
- Report wounds: Report any infectious
diseases or wounds to your supervisor before entering the facility.
- Avoid eating and drinking: Do not eat, drink, or
store personal belongings in the production unit, laboratory, storage, or
high-sterile areas.
- Follow SOPs: Follow the entry and exit
standard operating procedures (SOPs) strictly when entering each
area.
- Maintain hygiene: Maintain departmental
hygiene by wearing gowns.
- Avoid chemicals: Avoid using ornaments,
makeup, watches, perfumes, and other chemicals in the production
facility.
- Practice good habits: Take a daily bath, cut nails, comb hair neatly, and use hair covers
12.
Premises
Premises in the
pharmaceutical industry are buildings and facilities used for
manufacturing, processing, warehousing, packaging, labeling, and
testing. They must be designed, constructed, and maintained to meet
certain criteria to ensure the quality of products and prevent
contamination:
- Location: Premises should be located
in an environment that minimizes the risk of contamination. They
should also be compatible with other drug manufacturing operations in the
area.
- Design: Premises should be
designed to minimize errors and facilitate cleaning and
maintenance. They should have smooth, easy-to-clean interior surfaces
and be free from cracks.
- Lighting, temperature, and
ventilation: Premises
should have appropriate lighting, temperature, humidity, and
ventilation. Production and dispensing areas should be well lit and
ventilated.
- Equipment: Equipment should be stored
properly and calibrated regularly.
- Cleanliness: Premises should be kept
clean and disinfected according to written procedures.
- Access: Premises should be
designed to prevent unauthorized people from entering.
- Animals: Premises should be
designed to prevent the entry of insects, pests, birds, vermin, and
rodents.
- Working space: Premises should have
adequate working space to prevent mix-up between different categories of
drugs.
- Air conditioning: Air conditioning may be necessary for certain manufacturing operations.
13. Equipment
14.
Materials
·
The main objective of a pharmaceutical plant is
to produce finished products for patients’ use from a combination of materials
(starting and packaging).
·
Materials include starting materials, packaging materials, gases,
solvents, process aids, reagents and labelling materials.
·
No materials used for operations
such as cleaning, lubrication of equipment and pest control should come into
direct contact with the product. Where possible, such
materials should be of a suitable grade (e.g., food grade) to minimize health
risks.
·
All incoming materials and finished
products should be quarantined immediately after receipt or processing, until
they are released for use or distribution.
·
All materials and products should
be stored under the appropriate conditions established by the manufacturer, and
in an orderly fashion, to permit batch segregation and stock rotation by a
first-expire, first-out rule.
·
Water used in the manufacture of
pharmaceutical products should be suitable for its intended use.
15.
Documentation
In the pharmaceutical
industry, "documentation" refers to the comprehensive
recordkeeping of all processes, procedures, and data related to drug
development, manufacturing, and quality control, ensuring compliance with
strict regulatory standards by providing a detailed trail of activities and
decisions at each step, crucial for product safety and efficacy.
Key aspects of pharmaceutical documentation:
·
Good
Documentation Practices (GDocP):
A set of
guidelines ensuring accuracy, legibility, contemporaneity, and data integrity
in all recorded information.
·
Standard
Operating Procedures (SOPs):
Detailed
instructions for routine tasks, ensuring consistency across operations.
·
Batch
Records:
Comprehensive
records of each production batch, including raw materials, manufacturing steps,
quality control checks, and final product specifications.
·
Validation
protocols:
Documentation
of the process to confirm that equipment and methods consistently produce the
desired results.
·
Quality
Assurance (QA) records:
Documentation
related to monitoring and auditing quality throughout the manufacturing
process.
·
Clinical
trial documentation:
Detailed
records of study protocols, patient data, adverse events, and analysis
results.
Why
is documentation important in pharmaceuticals?
·
Compliance
with regulations:
Strict
regulatory agencies require robust documentation to verify product safety and
quality.
·
Traceability:
Documentation
allows for tracing the history of a product from raw materials to finished
product, enabling investigations in case of issues.
·
Quality
control:
By recording
data at each step, quality control teams can identify and address potential
problems early on.
·
Audit
preparedness:
Well-maintained
documentation facilitates successful audits by regulatory agencies.
Examples
of specific documents in pharmaceutical documentation:
Master manufacturing
instructions (MMIs), Change control documents, Calibration records, Stability
studies reports, and Deviation reports.
16.
Good practices in production
"Good practices in
production" refers to following strict guidelines known as Good
Manufacturing Practices (GMP), which ensure consistent production of
high-quality medicines by adhering to detailed procedures regarding personnel,
premises, equipment, raw materials, production processes, and quality control,
all aimed at minimizing risks of contamination, mix-ups, and errors throughout
the manufacturing process.
Key
aspects of good practices in pharmaceutical production:
·
Personnel
training:
All employees involved in production must be
adequately trained in GMP procedures, including proper hygiene practices,
handling of materials, and documentation requirements.
·
Cleanliness
and sanitation:
Maintaining a clean and well-sanitized
production environment is crucial, with strict protocols for cleaning and
disinfection of equipment and work areas.
·
Documentation
and record-keeping:
Detailed documentation of all production
steps, including raw material receipt, production processes, quality control
testing, and any deviations, is essential for traceability and
compliance.
·
Process
validation:
Manufacturing processes must be validated to
ensure consistency and reliability in producing the desired product
quality.
·
Environmental
monitoring:
Monitoring of environmental parameters like
temperature, humidity, and air pressure in production areas is necessary to
maintain appropriate conditions.
·
Cross-contamination
prevention:
Implementing measures to prevent
cross-contamination between different products, especially when handling potent
or hazardous substances.
·
Equipment
calibration and maintenance:
Regular calibration and maintenance of
production equipment are essential to ensure accurate operation and prevent
malfunctions.
·
In-Process
Quality Control:
Monitoring
critical process parameters during production to detect potential issues early
on.
17.
Good practices in quality control
Good quality control
practices include: thorough documentation and record-keeping, rigorous raw
material testing, comprehensive process validation, strict personnel training,
proper facility and equipment maintenance, robust product testing, effective
complaint handling, and adherence to change control procedures, all while
prioritizing patient safety and regulatory compliance, often guided by Good
Manufacturing Practices (GMP) standards.
Key aspects of good quality control in pharmaceuticals:
·
Quality
Risk Management:
Proactively
identifying and mitigating potential risks to product quality throughout the
entire product lifecycle.
·
Raw
Material Control:
Stringent
testing and quality checks on all incoming raw materials to ensure their
suitability for production.
·
Process
Validation:
Thoroughly
validating all manufacturing processes to guarantee consistent product
quality.
·
In-Process
Quality Control:
Monitoring
critical process parameters during production to detect potential issues early
on.
·
Product
Testing and Release:
Conducting
comprehensive testing on finished products to ensure they meet all quality
standards before release to market.
·
Stability
Testing:
Performing
stability studies to assess how a product degrades over time under different
storage conditions.
·
Change
Control:
Implementing
a formal system to evaluate and manage any changes that could affect product
quality.
·
Data
Integrity:
Maintaining
accurate and reliable data throughout the manufacturing process, including
proper documentation and data management practices.
·
Compliance
with Regulations:
Adhering to
all relevant regulatory requirements set by agencies like the FDA and
EMA.
·
Personnel
Qualification:
Ensuring all
personnel involved in sampling and testing are adequately trained and qualified
for their tasks.
·
Facility
and Equipment Maintenance:
Maintaining
clean and well-calibrated facilities and equipment to prevent contamination and
errors.
·
Complaint
Handling:
Having a
robust system to investigate and address customer complaints effectively.
·
Continuous
Improvement:
Regularly
reviewing processes and identifying areas for improvement to maintain high
quality standards.
The key principles of Good Manufacturing Practices (GMP) are:
- Establish and
enforce standard operating procedures (SOPs)
- Document all procedures and
processes
- Validate the effectiveness of
SOPs
- Design and implement efficient
working systems
- Develop employee competencies
- Regularly maintain systems,
equipment, and facilities
- Prioritize cleanliness to prevent
contamination
- Ensure quality is central to the
design, development, and manufacturing workflow
- Conduct GMP audits regularly