研发流程与QbD简介DS.ppt

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1、原料药工艺研发流程与原料药工艺研发流程与QbDQbD技术转化为价值GMP 医药化工法规约束稳定的工艺 实施GMP的基础QbD(质量源于设计）-工艺开发指导法规符合法规符合Quality by Design质量源于设计 前控制质量源于生产 过程控制质量源于检测 后控制法规符合法规符合Quality by Design质量源于设计质量源于设计Definition 定义定义Systematic approach to development that begins with predefined objectives and emphasizes product and process unders

2、tanding and process control,based on sound science and quality risk management.以以合理的科学和质量风险管理合理的科学和质量风险管理为依据的，起始于为依据的，起始于预定的预定的质量目标质量目标，注重，注重对产品和工艺的理解以及对生产工艺过对产品和工艺的理解以及对生产工艺过程控制程控制的的系统的研发方法系统的研发方法 Reference:ICH Q8(R)(2)Pharmaceutical Development,2009法规符合法规符合4What is Quality by Design?什么是质量源于设计什么是质量

3、源于设计(Reference:ICH Q8(R2),2009)法规符合法规符合Goals of Implementing QbD应用质量源于设计的目的应用质量源于设计的目的qAchieve meaningful product specifications that are based on clinical performance.根根据临床需求建立有意义的产品质量标准据临床需求建立有意义的产品质量标准qReduce product variability and detects by increasing product and process understanding通过对产品和其工艺

4、的理解，减少产品通过对产品和其工艺的理解，减少产品质量质量的变异和瑕疵的变异和瑕疵qEnhance product development and manufacturing efficiencies 提高产品开发和生产效率提高产品开发和生产效率qImprove post-approval change management改改善和方便批准后更改的管理善和方便批准后更改的管理QbD Terminology nQuality Target Product Profile 目目标产品质量概况标产品质量概况nCritical Quality Attributes 关关键质键质量属性量属性nCriti

5、cal Material Attributes 关键物料属性关键物料属性nCritical Process Parameters 关关键工艺参键工艺参数数nRisk Assessment 风险评风险评估估nDesign Space 设计空设计空间间nControl Strategy 控控制策制策略略nContinual Improvement 继续改进继续改进7Systematic Approach by QbDPredefinedObjective预定的目标预定的目标Defined Quality Target Product Profile(QTPP)Identify Critical Q

6、uality Attributes(CQA)ProductandProcessUnderstanding对产品和工艺的理解对产品和工艺的理解Define Critical Material Attributes(CMA)Identify Critical Process parameters(CPP)Understanding the relationship between CMA,CPP and CQAProcessControl生产工艺过程控制生产工艺过程控制EstablishappropriatecontrolstrategyDefineProvenAcceptableRange(PA

7、R)andOperationalRange(OR)SoundScience合理的科学合理的科学LiteraturePriorknowledgeDevelopmentstudyQualityRiskManagement质量风险管理质量风险管理Risk based approach through development to commercial manufacturing,as well as continual improvementOverview of QbD质质量源于量源于设计设计的概括的概括法规符合法规符合 Process Comparison 工艺比较工艺比较1QbD Concep

8、t ApproachTraditional Approach QTPP/CQA2Process Route IdentificationProcess Route Identification3Piloting Scale-up and Process OptimizationPiloting Scale-up and Process Optimization4Process Characterization and Process Understanding vCPP,CMA,PAR(OR)5Control strategy(Design Space,etc.)6Process Qualif

9、ication(Validation)Process Qualification(Validation)10ProcessDevelopmentProcedure-产品开发流程产品开发流程路线评估路线评估工艺开发工艺开发/路线确定路线确定工艺优化工艺优化工艺确认工艺确认放大研究放大研究工艺验证工艺验证明确目标明确目标商业化商业化生产生产QTPP/CQAQTPP/CQA（杂质、晶型、粒度等）（杂质、晶型、粒度等）文献综述文献综述 路线可行性分析（成本、绿色、设备、质路线可行性分析（成本、绿色、设备、质量、原料）合理的科学和技术积累量、原料）合理的科学和技术积累 创新创新起始物料确认，每步考察，最

10、终工艺确定起始物料确认，每步考察，最终工艺确定 确定确定潜在产品质量属性及潜在产品质量属性及初步质量风险评估初步质量风险评估每步工艺优化每步工艺优化 CPPCPP确认确认/优化工艺优化工艺 质量风险控制质量风险控制 DoE DoE Design Space(Design Space(允许允许/操作范围操作范围)实验室三批确认实验室三批确认放大工艺放大工艺/步骤合理性说明步骤合理性说明/评估评估验证方案验证方案/验证报告验证报告ContinuousProcessImprovement11Example Identify CQA in Drug SubstanceQualityAttributes

11、TargetCriticalJustificationSolidStateFormIIYesDirectlylinktosolubility&stabilityPSDDefinedrangeYes/NoFormulationandprocessdodependentAssay(purity)100%oflabelclaimYesAssayvaluewillaffectsafetyandefficacySolubilityInformationNoNotcontrolbyprocessDegradationProductsXXX:NMT0.5%AnyunknownNMT0.2%Total:NMT

12、1.0%YesTheymayimpactsafetyWaterContentNMT4.0%NoUnlikelytoimpactsafetyQuality Risk Management ProcessProcessDevelopmentControlStrategyDevelopmentContinualImprovement13Risk Assessment Tools风险评估的工具估的工具pTools for parameter screeningExamples:Ishikawa(Fishbone)diagrams,What-if Analysis,HAZOP analysispTool

13、s for risk rankingExamples:FMEA/FMECA,Pareto analysis,Relative rankingpExperimental tools for process understandingExamples:Statistically designed experiments(DOE),mechanistic models14Selected Tools Used in the Risk Assessment 用于用于风险评估的工具估的工具举例例pIshikawa(Fishbone)Diagramto identify all potential var

14、iables,such as raw materials,compression parameters,and environmental factors,which can have an impact on a particular CQA,such as tablet hardness.pFailure Mode Effect Analysis(FMEA)to rank the variables based on risk(i.e.,a combination of probability,severity,and detectability)and to select the pro

15、cess parameters with higher risks for further studies to gain greater understanding of their effects on CQAs.15Ishikawa(Fishbone)DiagramsAlso known as Cause&Effect DiagramIncludes all the potential inputs that affect a desired output(CQA)Effective for initial brainstorming of potential design space

16、parametersQualityAttribute(Effect)MaterialAttributesProcessParametersOperationalFactors(Causes)16Failure Mode Effects Analysis(FMEA)Cross-functional team evaluation Product and process understanding appliedPotential failure modes identified and related to product quality and performanceProduct and p

17、rocess risks prioritized Output/results can be used as a basis for design of experiment or further analysisRisk quantitatively assessednRisk=Severity X Likelihood X Detectability严重性严重性 X 可能性可能性 X 可可测试性测试性 17CriticalQualityAttribute(right)AppearanceChemicalIdentityPhysicalIdentityResidualPrecursorsS.

18、M.RelatedImpuritiesProcessRelatedImpuritiesEnantiomericPurityPhthalimideProductsEDC.HCl+ureaby-productDMAPmethylamineInorganicSaltsDMFDichloromethaneIsopropanolEthanolAceticAcidAcetoneAssayParticleSizeStability/StorageProcessStage(below)StartingMaterialRIA10StartingMaterialRIA20RIA30ReactionIsolatio

19、nDryingRIA35ReactionIsolationDryingRIA46ReactionWork-upStartingMaterialRIA60RIA56ReactionWork-upRIAReactionIsolationPurificationDrying/MillingOverallPreliminaryProcessRiskAssessmentMap18Design Space 设计空空间Definition 定义定义The multidimensional combination and interaction of input variables(e.g.,material

20、 attributes and process parameters)that have been demonstrated to provide assurance of quality输入变数输入变数(物料属性和工艺参物料属性和工艺参数数)的多维结的多维结合和相互作用已证明能合和相互作用已证明能提提供产品质量的保障供产品质量的保障vWorking within the design space is not considered as a change.Movement out of the design space is considered to be a change vDesign

21、 space is proposed by the drug applicant and is subject to regulatory assessment and approval19Design Space 设计空空间 Design space is potentially scale-and equipment-dependent 设计空设计空间与批量和设备有关间与批量和设备有关Design space determined at the laboratory scale may not be relevant to the process at the commercial sca

22、le 实验或小试中取实验或小试中取得的设计空得的设计空间也许与商业间也许与商业生产工艺没有直接的关联生产工艺没有直接的关联 Therefore,design-space verification at the commercial scale becomes essential unless it is demonstrated that the design space is scale-independent.与生产批量有与生产批量有关的设计空关的设计空间参数间参数应在商应在商业批生产过程中证实业批生产过程中证实20Important NoteFor generic drug/API ap

23、plications:pDesign space is optionalpQbD can be implemented without a design space because product and process understanding can be established without a formal design space.pImplementation of QbD is strongly encouraged by FDA.For some complex drug substances or drug products,implementation of QbD i

24、s considered a required component of the application.21Control Strategy控制策略控制策略ICH Q8 defines Control Strategy as:qA planned set of controls,derived from current product and process understanding that ensures process performance and product quality.基于在对产品和工艺的理解基础上制定的控制要点以确保工艺稳定基于在对产品和工艺的理解基础上制定的控制要点

25、以确保工艺稳定和产品质量和产品质量The controls can include parameters and attributes related to drug substance and drug-product materials and components,facility and equipment operating conditions,in-process controls,finished-product specifications,and the associated methods and frequency of monitoring and control.2

26、2Control Strategy控制策略控制策略Control strategy may include:Control of input material attributes(CMAs)Controls for unit operations(CPPs and process endpoints)In-process or real-time release testing Product specifications(CQAs)23CriticalQualityAttribute(right)AppearanceChemicalIdentityPhysicalIdentityResid

27、ualPrecursorsS.M.RelatedImpuritiesProcessRelatedImpuritiesEnantiomericPurityPhthalimideProductsEDC.HCl+ureaby-productDMAPmethylamineInorganicSaltsDMFDichloromethaneIsopropanolEthanolAceticAcidAcetoneAssayParticleSizeStability/StorageProcessStage(below)StartingMaterialRIA10StartingMaterialRIA20RIA30R

28、eactionIsolationDryingRIA35ReactionIsolationDryingRIA46ReactionWork-upStartingMaterialRIA60RIA56ReactionWork-upRIAReactionIsolationPurificationDrying/MillingOverallOptimizedProcessRiskAssessmentMap24CriticalQualityControlStrategyofDrugSubstanceCriticalQualityAttribute(TestMethod)DSConfirmationTestAc

29、ceptanceCriteriaProductQualityControlTypeDescriptionofControlsAppearance(Visual)Whitetooff-whitepowderStartingMaterials(RIA10,RIA60)&RIAProcess:RIA35Isolation&RIACrystallizationRIA10 Appearance Specification(white to light brownsolid);Filtered&washed,RIA35AppearanceSpecification(whitetooff-whitesoli

30、d);RIA60 Appearance Specification(white to dark beigesolid);FiltercakewashofcrudeRIAandcrystallizedRIAensurescolourremoval.ChemicalIdentification(IR)The IR absorption spectrum of thesampleexhibitsthemaximaonlyatthesame wavelengths as that of thecorrespondingstandard.StartingMaterials(RIA10,RIA20,RIA

31、60)&GeneralCGMPRIA10,RIA20&RIA60IdentificationSpecification;ChemicalIdentification(HPLC)The retention time of the principlepeak in the chromatogram of thesample preparation conforms to thatofthereferencestandardpreparationobtained as directed in the Assaymethod.StartingMaterial(RIA10,RIA60,phthalimi

32、depotassium,)&GeneralCGMPRIA10,phthalimide potassium&RIA60 IdentificationSpecification.25Process Development Report工艺硏发报吿工艺硏发报吿 qAll written documents should follow Good Document PracticeDocument numbersAuthor and approver signaturesData traceability(notebook numbers)Individual report can reference

33、other reports26ProcessDevelopmentReport工艺硏发报吿工艺硏发报吿 qNot a written regulatory requirementqAbsence of the report is not a reason for a FDA-483 observationHowever,vCompanies must produce documented data to justify critical process parameters,controls ranges and specifications,etc.vNo documented suppor

34、tive data will result in 483 observation(GMP deficiency).27ProcessDevelopmentReport工艺硏发报吿工艺硏发报吿 qObjectiveSummarize development history to support proposed commercial processSupport qualification/validation protocolDemonstrate knowledge and control strategy over the commercial process Prepare for Pr

35、e-Approval Inspection(PAI)Reference for future optimization and investigation activities,such as OOS and deviationsSupport CMC/DMF filing(Section 3.2.S.2.6)281.Introduction:DrugSubstanceIdentityandAttributes2.SyntheticRouteDevelopmentEvaluation3.PotentialQualityAttributesoftheDrugSubstance4.Prelimin

36、aryRiskAssessmentforCriticalQualityAttributes5.StartingMaterialDiscussion6.OptimizationofManufacturingProcess7.Manufacturing7.1.BriefDescription7.2.SyntheticScheme7.3.DetailedDescriptionoftheProcessControl8.CriticalQualityControlStrategyofDrugSubstance9.HistoryofManufacturingProcessProcessDevelopmen

37、tReport-产品开发报告产品开发报告29Attachments:SupplierSpecificationsforStartingMaterialSpecificationsforStartingMaterialandIntermediatesProcessControlMapDetailedRiskAssessmentCofASummaryofManufacturedBatchesGlossaryofAbbreviationsProcessDevelopmentReport-产品开发报告产品开发报告30QbD-产品开发流程产品开发流程工艺开发报告工艺开发报告比较比较QbD工艺开发工艺开发

38、产品开发报告产品开发报告QTPP/CQA目标产品质量标准目标产品质量标准引言引言-产品介绍产品介绍及要求及要求工艺设计与风险评估工艺设计与风险评估工艺路线评估工艺路线评估/路线选择路线选择与确定与确定路线选择与开发路线选择与开发潜在质量属性确定潜在质量属性确定初步风险评估初步风险评估起始物料确定起始物料确定风险控制策略风险控制策略工艺优化工艺优化/确认确认/放大放大/验证验证生产工艺优化生产工艺优化生产工艺控制生产工艺控制产品质量控制策略产品质量控制策略持续改进持续改进商业化生产商业化生产生产批次历史生产批次历史/年年报报分析分析31Quality by Design质量源于设计目标：设计和开发的工艺能够在可控风险的情况下生产出符合质量标准的产品满足产品质量要求的工艺开发是执行GMP全过程的基础-全程可全程可控控法规符合法规符合