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January 19, 2024, vizologi

Real-World Examples of Process Validation

Products and services are always changing. It’s more important than ever to validate processes. Process validation is seen in many industries, from manufacturing to healthcare. It’s used to ensure the safety and effectiveness of drugs and the quality of car parts. Looking at real-world examples helps us understand the significance of process validation today.

Understanding How We Make Sure Products Work Right

Explaining What it Means to Check Products

To ensure products are made properly in the MedTech industry, it’s important to follow key steps. Process verification and validation play a crucial role in ensuring consistent and correct production. It’s essential to understand the differences between these steps and know when to use each in medical device manufacturing.

Keeping records of product checks and quality control measures is important to meet ISO 13485:2016 and 21 CFR 820.75 requirements, and to ensure that centralized Quality Management Systems (QMS) are in place.

Following process validation steps, such as IQ, OQ, PQ, and process risk analysis, is important to meet predetermined specifications and ensure that a process consistently produces the expected results. Additionally, maintaining documentation is vital for additional sterilization validation procedures, to confirm that a product meets its intended results.

Explaining How We Make Sure Products are Made Right

During the planning and design stage, specific steps are taken to make sure products are made correctly. This includes conducting a risk analysis to identify potential areas of failure or quality issues.

Additionally, design verification and validation activities are carried out to confirm that the product design meets the specified requirements and user needs.

Throughout the production process, the determination to check products or ensure they are made correctly is based on established checkpoints and predefined criteria. This involves conducting in-process inspections, testing, and monitoring at various stages to verify that the product is being manufactured as required.

To make sure that every product is thoroughly checked for quality before being released, measures such as process validation, product testing, and inspection protocols are implemented. This includes conducting final product inspections to assess conformance to quality standards and regulatory requirements, as well as verifying that the product meets customer expectations before it is cleared for release.

Deciding When to Check Products or Make Sure They’re Made Right

Determining when to check products is important. Consider the stage of the process and the intended result. In the development process, ensure outcomes meet the specified requirements (Design Input). For sterilization, verify that the product is sterile. Factors to consider include the need for objective evidence that the process consistently produces a result meeting its predetermined specifications. This evidence confirms the fulfillment of requirements for a specific use.

Not checking products can lead to serious implications, like inconsistent production that impacts the quality and safety of medical devices.

The Steps to Making Sure Products are Made Right

Stage One: Planning and Design

During the planning and design stage for product quality, some important decisions are made. These include figuring out how the product will be used and what the requirements are. It also involves deciding on the specific process that needs to be checked to ensure quality. This stage helps in defining the process and its intended results. It also helps in identifying important process factors and acceptance criteria.

Additionally, it sets the stage for deciding how and when to check the products. This includes methods like installation qualification, operational qualification, performance qualification, and risk analysis. The complexity of the process, its criticality, and the impact on safety and effectiveness influence when and how to check the products.

Stage Two: Testing a Sample Product

During Stage Two of the product development process, specific methods and criteria are used for testing a sample product. One method used is the Master Validation Plan (MVP) form, which outlines the stages of process validation. These stages include Installation Qualification (IQ), Operational Qualification (OQ), Performance Qualification (PQ), and process risk analysis.

The goal of Stage Two is to ensure that products are made right by establishing a process that consistently produces a result meeting predetermined specifications, as defined by the FDA. Key considerations for deciding when to move a product to the next stage or modify the sample product based on testing results include understanding the scope of the procedure, having a centralized Quality Management System , meeting ISO 13485:2016 and 21 CFR 820.75 requirements, and addressing the requirements for sterilization validation.

Stage Three: Checking Every Product

Stage Three involves specific processes and procedures to validate every product. This includes conducting IQ, OQ, and PQ processes for every product. By implementing these procedures, consistency and accuracy in checking every product is achieved, ensuring its quality and performance.

Any discrepancies or issues found during the checking process are addressed by conducting a thorough process risk analysis. This involves following the outlined process validation procedure, SYS-014, as per ISO 13485:2016 and 21 CFR 820.75 requirements.

It’s important to understand the process validation steps, offering the opportunity to rectify any discrepancies or issues found during the checking process.

Where You Should Keep All the Records

Records for product planning, design, testing, and checking should be stored in a centralized Quality Management System in the MedTech industry. This helps make sure that all needed documentation is easy to access for review and audit. Organizing and storing records properly can help oversee product quality control processes more efficiently by tracking changes, updates, and approvals easily.

This is especially important for process validation to ensure consistent production of correct results. Best practices for maintaining confidentiality and security of product records include access controls, regular backups, encryption of sensitive data, and maintaining an audit trail of all changes. Following these best practices ensures that product records are secure and comply with industry regulations.

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