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1.        Instructions describing backup and restore     Refers to the creation of the  official documents describing in detail exactly how backup and restore  routines are performed     Suggested Documentation   1   A Backup instruction  describing in detail exactly how a complete backup  1s performed     2   A Restore instruction  describing how the contents of a media containing  a backup are restored  partially or totally     Amersham         Biosciences  25    UNICORN 5 0N    6 3     6 4     6 5        Handling security instructions    are the instructions describing how and  where backup media should be handled and stored     Suggested Documentation  Instructions regarding    responsibilities   frequency for backup  generation handling   handling of media containing backup  storage and accessibility  who has the authority to order the use of a backup   when backup media is  worn out  and should be replaced  person s  in the system responsible for the backup restore  changes in backup routines   log for backups  labelling of media  e g   tapes     Installation Qualification  IQ     Installation Qualification is defined normally as    documented verification that all important  aspects of installing the hardware and software adhere to the computerised system specification   Installation qualification also includes verification that there are appropriate manuals  as built  drawings  instrument calibration reports  and instructions on the operation and maintenance of the  syst
2.     Placebo Batching    Edition AB   January 2004    Is the use of simulated product to confirm that the computerized system performs  in the desired manner  The placebo batches should be made both in accordance with  the routine process  uneventful   to confirm proper sequence  or outside the norm   eventful   to confirm the appropriate response to anticipated process or system  upsets   The placebo batch confirms the acceptability of the computerized system   Placebo batches should be made for every product to be made in the system  In  some instances it may be necessary to make both maximum and minimum placebos  to assure that process parameters  alarms  and sensor locations are appropriate for  all batch sizes  Placebo batching is also used for non product operations such as  cleaning     Amersham         Biosciences  16    UNICORN 5 0N    5 5 3  System Level Verification    Verification of system performance under actual use is called System Level Verification   This is performed at the user s site     Product Batching    Batches of actual product are produced in the system using full automation  The  batches produced are subjected to full validation testing to ensure their conformance  to the required product specifications  No intentional upsets are introduced into the  process  The successful production of product establishes the suitability of the  system to make releasable material  Comparable verification is performed on other  automated activities managed by the c
3.    Amersham Biosciences has a unique knowledge how FPLC       KTA  BioPilot     BioProcess   OligoPilot and OligoProcess systems have been developed and verified  To system owners  this  knowledge and documentation should be of interest in the validation process  assuring that  Amersham Biosciences utilises procedures and documentation which complies with accepted  standards throughout the pharmaceutical industry     Amersham    e Biosciences    Edition AB   January 2004 1    UNICORN 5 0N    The following picture  UNICORN validation  illustrates the relations between the system owner   Amersham Biosciences and activities and documentation which should be involved in the  validation process for a UNICORN based chromatography system     UNICORN Validation          Protein  eparations    Installation      de Documentation provided or available from Amersham Biosciences  Support available from Amersham Biosciences Fast Trak    System Owners input or documentation       BMI refers to the instructions and procedures used by Amersham Biosciences in the  development of the system  See Section 3 Amersham Biosciences Quality Management  System     System Owner is the person at the users site who is responsible for the correct functioning  of the system     UNICORN refers to the documentation produced during the development of UNICORN     System Doc is the system specific documentation supplied to the system owner from  fabrication and final testing of the individual system     Installa
4.    Sw development handbook 70 5012 08    4 3  Service  Maintenance and Spare parts    Labcrew     Amersham Biosciences instrument service group delivers the background technical  maintenance  expertise and service that keeps science running smoothly     Each member of our service team has the capability to quickly assess a situation  identify  problems  and deliver rapid corrective measures on site  From preventative maintenance and  instrument repair to software and hardware upgrades  Labcrew keeps your equipment in peak  condition     Spare parts can be ordered through your local Amersham Biosciences office  Most commonly  used parts are stored locally  and can be provided immediately  Your local office will also be  pleased to arrange delivery of specialist spare parts from our global distribution centres     On call from our service centres worldwide  Labcrew   s mission is to keep your science on track    4 4  Error Reporting    In order to ensure that correct actions are taken when an error is reported on a product  Amersham  Biosciences follows documented routines to ensure correct handling and feedback to customers at  all times     Users shall always report product issues to the local Amersham Biosciences representative for  further action     Amersham    PE e Y  Biosciences  Edition AB   January 2004 13    UNICORN 5 0N    5  COMPUTERIZED SYSTEM VALIDATION    5 1  Introduction    The following text provides a brief description of each of the tasks necessary to comple
5.    optional     MDD    sw Module Design  Description    or documentation in  SDD  code  model    MTD    sw Modulte Test  Description    MTR    sw Module Test  Report    11    ITR    sw Integration Test  Report    STR    sw System Test Report    CEV    sw Computer  Equipment Verification  report    SVD    Sw Version Description       3  part evaluation   optional     sw QA audit report    sw Approval for  Use minutes     Bug list  implemented as  extract from    dbPlus     Sw development handbook 70 5012 08  section Sw steps and documents  See BMI for document number of the templates    MES OI     gt  7  Biosciences    UNICORN 5 0N    The output from the software development results in an executable  documented  verified and  archived software system     Amersham    E e Y  Biosciences  Edition AB   January 2004 12    UNICORN 5 0N    The figure    Test descriptions and reports during Verification    summarises the verification  performed on the different levels  including the documents used to describe the test cases and the  test result     Test descriptions and reports during Verification                tus  e   i GAMP level  Additional verification at customer site 10  00  PQ  System verification Verification report System  Verification Verification report Integration    sw test description in SVP  70 5000 13  D procedure 70 5010 05    Sw application SVP SVR report i abe  Sw requirement STD STR report Module  Sw integration ITD ITR report Code  Sw module MTD MTR report Code 
6.   5 3 2  Piping  amp  Instrument Drawing    a iii 14  5 3 3  Instrument Listin o 15  5 3 4  Input Output Las tsi cri ota 15  5 3 5  Waring  Checks E de A onda 15  5 3 6  Component Qualification vse  4 lorelai ala 15  5 3 7  Calibration   WA A hep gna di dans eave AS na 15  5 4  SOFTWARE DEVELOPMENT   VERIFICATION PHASE                  corno nrrn nn rre nnr rn 15  5 4 1  Quality Assurance Methods for Software Development                i 15  5 4 2  Process Operation io ra AR a mined Saad 15  5 4 3  Program Description  Application Code                    sense eeeeeeeetennneaeeeeeeeeeeeennnneeeeeeeentee 16  5 4 4  Software Structural Description  usage sara so cepa id da erage ate esa guita Seats 16  5 5  SYSTEM INTEGRATION AND VERIFICATION PHASE               non nonnnon anar o nro nrnn nr ana nnnn rr anna 16  5 5 1  Module Level Veritat ott  a renali 16  5 5 2  Program Level Verification  ici ii iii 16  5 5 3  System Level VeA CAT O raa a aaa Lila licitador 17  5 5 4  Additional Software Verification Requirements                    ii 17  5 6  OPERATIONAL PHASE a  sibili alati nella 17  5 6 1  Charige Control    iis aria a air 17  5 6 2  System Recovery Placa ia ela ale 17  5 6 3  Operating  Manuals    ito aida aida 18  5 6 4  Trainingof Persontiel iia 18  5 6 5  S  pport Personne leser cenana a ins docas aleta 18  5 6 6  System Security saose ienaa ins aa  ade deta aaa aa a ia a aa a aaa ai tee 18  5 6 7  Operating  Procedures    ridad eta 18  Amersham    o e Y   Bioscienc
7.   The following versions of UNICORN have been released from Amersham Biosciences  in  chronological order       UNICORN version Released Operating system    1 10 Sept  1994 OS 2    1 11 Dec  1994 OS 2  1 12 Feb  1995 OS 2    Oct  1996  3 00 May 1998  NT  NT                   Amersham    o e Y   Biosciences  Edition AB   January 2004 3    UNICORN 5 0N    OBSERVE     Upgrading software in a system may have an impact on its functionality  and a  revalidation may be necessary  This should be evaluated prior to performing  any modification or upgrading of the software     2 3  Independent UNICORN Audits    Already when the first version of UNICORN was developed  an independent company  Weinberg  Associates Inc  audited the principles and procedures employed by Amersham Biosciences in the  development of UNICORN  As a result of this audit  Amersham Biosciences obtained a  certificate  which confirms that the development model complies with relevant regulatory  standards     Compliance with the FDA 21 CFR Part 11 was obtained starting with UNICORN 3 2     Certificate and audit report from UNICORN 5 0 is included in this support package     Amersham    o e Y  Biosciences  Edition AB   January 2004 4    UNICORN 5 0N    Certification of  UNICORN 5 0    Amersham Biosciences    The UNICORN 5 0 software of Amersham Biosciences  has been audited on 11 12 December  2003   and found to be in full compliance with FDA Regulation 21CFR Part 11 and  applicable sections of the regulations Good Ma
8.   Validation Documentation from Amersham Biosciences Fast Trak Validation    In order to facilitate the successful start up of systems at customer sites  Amersham  Biosciences Fast Trak Validation has developed a comprehensive set of system  qualification protocols  The protocols address process equipment and control  system documentation  The qualification protocols are not a part of this validation  support documentation  They are available separately from Amersham Biosciences  Fast Trak Validation     In addition Amersham Biosciences Fast Trak Validation offers a SOP package that  consists of the following SOPs    Back up   Restore   Revalidation   Log book   System security   Audit trail    7  REFERENCES    1  Audit Report  Amersham Biosciences UNICORN Version 5 0  see separately attached file   2  UNICORN 5 0 21 CFR Part 11 System Assessment checklist  see separately attached file     3  Validation concepts for computer systems used in the manufacture of drug products  PMA   s Computer  System Validation Committee  Pharm  Technol    1986   Vol  10  No  5  24 35    4  Computer system validation     staying current  Vendor User relationships  PMA   s Computer System  Validation Committee  Pharm  Technol   1993   Vol  5  No  8    Amersham    pa e Y  Biosciences  Edition AB   January 2004 34    UNICORN 5 0N    Trademarks    UNICORNTM  FPLC     AKTA     BioPilot     BioProcessTM  OligoPilot     OligoProcess    and Labcrew    are  exclusive trademarks of Amersham Biosciences L
9.   develop ment Product performance  Refined requirements in verification  amp  validation Project review and  swTS  lwTS      end of life    recommend ations    Project planning in  OPP       Requirements in target  TS   P  Third nning   Barty pla Product information Production process    develop ment validation  Financial analysis IPR review       Phase 1 Exit review Phase 2 Exit review Phase 3 Exit review Phase 4 Exit review Phase 5 Exit review       A Phase Reviews by Business Area      Peer technology reviews Procedure for Development  D  project 70 5010 05        Amersham    A e Biosciences    UNICORN 5 0N    For software development  additional procedures are used  Figure    swBMI steps    shows the main  activities  These procedures also contain information regarding responsibilities  verification   reviews and approval  error handling etc  Templates forms are also available  see Figure     Available templates         Project planning    swBMI steps    Sw project planning including test plans in SDP       Project planning    HIS    sw Human Interface  Specification    SRS    Sw Requirement  Specification    STD    sw System Test  Description    Edition AB   January 2004       Sw development handbook 70 5012 08    Available templates    SDP  Sw Development Plan    SDD    Sw Design Description    IDD    sw Interface Design  Description  option     CEV    sw Computer  Equipment Verification  description    ITD    sw Integration Test  Description    Co operation routines  
10.  and complicated task   Amersham Biosciences Fast Trak offers expert services in process optimization  The main  goal of process optimization is to develop a method that produces a product of a desired  purity and quantity    Process Optimization includes several steps     Raw material considerations   Specification of the process   Choice of techniques    Number of chromatographic steps   Yield in each step    Method scouting    Method optimization    Economic considerations    Scale up and adjustments    Media life length    Cleaning in place  CIP     System sanitation    Other activities relevant for the development of the individual process        These activities will generate documents  which will be beneficial to the verification of the  process  Accordingly  all relevant documentation should be created and properly stored     6 5 4  Method Construction    As there are many aspects of how a program should be constructed and how programming  should be performed  no recommendations are suggested here  Regardless of the method  used for programming  documentation should be created to support and verify the function  ofa program     Examples of such documents are     Functionality model    A list of all variables and description of their function    Limits for variables and fields    Method instructions    Description of all modules and subroutines in the program and their functions   Signatures and dates of the responsible programmer s     Descriptions of all alarms and w
11.  maintaining documentation on requested changes  etc     Process Operating Logic    Detailed descriptions of the various procedures to be carried out by the system  It is  developed by personnel knowledgeable in the pharmaceutical process for the purpose of  communicating process information to the programmer  It indicates the routine process  as  well as the desired response to likely process upsets  data entry errors  component failures   etc  Logic flow diagrams are sometimes employed for this purpose     Amersham  s e Biosciences    Edition AB   January 2004 15    UNICORN 5 0N    5 4 3  Program Description  Application Code     Paper and or electronic copies of the software that are to be validated  The annotation of  source code is highly desirable as a means of initial preparation  audit and subsequent  change  At this stage the software can be audited but it cannot be rigorously tested until it  is installed on the hardware     5 4 4  Software Structural Description    An overview of the software defining the various programs  including modules  and their  functions   their relationship to each other  any sub routines and sub programs  It  sometimes includes additional information such as protocol lists  batch sequences  alarm    points     etc  that are utilized     5 5  System Integration and Verification Phase    Once the hardware installation and software development is complete  the project enters the  integration and verification phase  Here the software and hard
12. ND OPERATIONAL QUALIFICATION SERVICES FROM AMERSHAM  BIOSCIENCES FAST TRAK VALIDATION               tsten etenn Enne EEES EE EEE EEEE EEEEEEEEEEEEEEEEEEEE EEEE EE EEEE EE 34  7  REFERENCES e aTa ae ar aa a Ea cia 34  Amersham    o e Y   Biosciences  Edition AB   January 2004    UNICORN 5 0N    1     2     2 1     INTRODUCTION TO THIS DOCUMENT    This support package is valid for all UNICORN    versions 5 0N  The last  third  digit has been  replaced with a letter    N      see 2 2 in this document     The document has been assembled to provide important information on the development and  documentation of UNICORN 5 0N  It will assure system owners that UNICORN has been  developed in a structured manner  and verified in accordance with the System Development Life  Cycle concept  The proper development  verification  and documentation are vital to the  functionality and performance of UNICORN when in operation at a customer   s site  and should   accordingly be of interest to system owners     This document gives an overview of how UNICORN is developed  It would have been desirable  to include all the documents created during the development of UNICORN 5 0N in this  information package  but this is not practical and realisable  Customers  who wish to verify the  existence of the documentation and development procedures  may perform audits in Uppsala  and or in Ume    Sweden     This document provides a comprehensive description of the validation of the UNICORN system  that cont
13. OQ Services from Amersham Biosciences Fast Trak Validation  which will  provide a customer with test protocols and documentation proving that the system is capable of  performing its required functions     Method Development and Verification    The development of methods are dependent on many factors as the system is complex and allows  the user to freely construct and make modifications as desired  Method development is of great  importance to the demands you may have on documentation  security levels  and operating  procedures    An   KTA system used for scientific research normally has much lower requirements in these  aspects than a BioProcess systems which is used under FDA regulations to produce  pharmaceuticals  The level you choose is highly dependent on the systems use    It may appear unnecessary to apply this way of developing systems in many cases  such as R amp D  activities  however  it is common that processes are developed on an   KTA and scaled up to a  BioProcess system at a later stage  If this is the case  structured development and good  documentation will be beneficial to the scaling up and documentation of the process at a later  stage     Amersham  s e Biosciences    Edition AB   January 2004 26    UNICORN 5 0N    It is recommended that the system use is determined first  and then the required level of quality   These two factors should be the fundamentals for the development of your own methods  Keep in  mind that you never can test quality into your 
14. Q of the system     The following figure illustrates an example of an Activity Schedule with sub levels   describing the development of a backup system     Amersham    pa e Y   Biosciences  Edition AB   January 2004 21    UNICORN 5 0N    Activity Schedule    Amersham    E e Y  Biosciences  Edition AB   January 2004 22    UNICORN 5 0N    Amersham    e Y  Biosciences  Edition AB   January 2004 23    UNICORN 5 0N    Target Finished  Activit Responsible date    Activity 1 2003 12 10  Activity 2   B  Berg  2003 12 15       Backup   G  Gren  2003 12 24       Activity 4   S  Stenson  2003 12 31       Activity N       Olsson  200N NN NN       N                          select technique  y  Activity 1 purchase of equipment  y    Activity Scedule a install HW SW  a A Activity 2    i Tl tal a x y select procedure  amp  routines    Activity 4 tenson  2003 12 31             Activity Responsible at dat  Activity 4 2003 12 10   2003 12 08  Activity 2 erg   2003 12 15                                           Activity N ison  200N NN N    Activity N N N  200N NN NN N B a C k u p ua i 3                test of back up  a  SOP s desc  BU  Restore  g  handling security SOP s                Activity 4                               The Activity Schedule should in this case contain information describing who is  responsible for the development of a backup procedure and a date when this activity should  be finished  It should also refer to the    Backup    activity document  below   in which more  d
15. UNICORN 5 0N    FAST  _  a  TRAK    VALIDATION    UNICORN Validation Support Package  for    UNICORN 5 0N    i Amersham  04 0021 58 e Y  Biosciences    UNICORN 5 0N    TABLE OF CONTENTS    1  INTRODUCTION TO THIS DOCUMENT                                cicci 1  2  INTRODUCTION TO UNICORN VALIDATION                                iii 1  2 1  GENERAL UNICORN INFORMATION    1  2 2  VERSION  NUMBERING goreh ra aea i add PARI FARAI ICRA RO Re nantes nb ig ana ta 3  23  INDEPENDENT UNICORN AUDITS eiieeii piee quedare candrinoda iaia era aaa 4  3  AMERSHAM BIOSCIENCES QUALITY MANAGEMENT SYSTEM                                  7  3 1  INTRODUCTION java tina strass avian iinet Wacken den a ola lM eee ees 7  3 2  PROTEIN SEPARATIONS QUALITY POLICY            iii 7  3 3  TSO  CERTIFICATION  60d AA RR 7  4  PRODUCT DEVELOPMENT    ail lei 9  4 1  INTRODUCTION ili tandas 9  4 2  DEVELOPMENT MODEL ronisin er lide ans dt decai ei Dia so db inte 9  43  SERVICE  MAINTENANCE AND SPAREPARTS                    13  44  ERROR REPORTING uta taa epi an tadas 13  5  COMPUTERIZED SYSTEM VALIDATION                        iii 14  5 1  INTRODUCTION anaa aa a a aa a aa id tia 14  32  DESIGN  amp  SPECIFICATION  PHASE did lindaa cid 14  5 2 1  Functional Requirements  aria 14  5 2 2  System Specification  T ria iii 14  5 3  HARDWARE INSTALLATION  amp  QUALIFICATION PHASE  0oococccccononnnncnccnnnnnonnnnnncnnnnnnnnnnnnnnnrnnnnnnnnnnns 14  5 3 1  System Description with Schematic Drawings                 i 14
16. achieved ISO 9001 certification in February 1993  On September 26   2003  the company received Certificate of Approval to the Quality Management System Standard  ISO 9001 2000  see certificate below      Amersham    pa e Y  Biosciences  Edition AB   January 2004 7    UNICORN 5 0N    CERTIFICATE OF APPROVAL    This is to certify that the Quality Management System of     Amersham Biosciences  Uppsala  Sweden    has been approved by Lloyd s Register Quality Assurance  to the following Quality Management System Standards     ISO 9001   2000  The Quality Management System is applicable to     Research  design  development  procurement  manufacture   marketing  sales  service  support and distribution of chemicals   instruments and services for separation  characterization   quantification and synthesis of biomolecules     Approval Original Approval  19 February 1993  Certificate No  655790  Current Certificate  26 September 2003    Certificate Expiry  28 February 2005    Issued by  LRQA  RotteNdam     This document is subject to the provision on the reverse  This approval is carried out in accordance with the LRQA assessment and certification procedures and monitored by LRQA   The use of the UKAS Accreditation Mark indicates Accreditation in respect of those activities covered by the Accreditation Certificate Number 001  Aimes oor 161       Pa Amersham    Biosciences  Edition AB   January 2004 8 es    UNICORN 5 0N    4  PRODUCT DEVELOPMENT  4 1  Introduction    Amersham Bioscience
17. arnings    Protocols from tests performed by the programmer s     Security and access levels    Other relevant information     Amersham    Da e Y  Biosciences  Edition AB   January 2004 28    UNICORN 5 0N    When a program has been constructed by the programmer s   it should be subject to testing  and evaluation in order to be approved for use as intended    The testing procedures are dependent on the demands and validation level intended for the  system  and cannot  therefore  be specified here  The test should not only prove that the  program performs as intended  but should also include  worst case  simulations in which  warnings and alarms are triggered  These tests should not be carried out or constructed by  the person s  who constructed the program     Suggested documentation     Test plan    Test description    Responsible and responsibilities   Criteria for approval    Protocol from test    Criteria for approval of test   Other relevant documentation     6 5 5  Backup   Restore    Backup and restore are preventive actions to avoid accidental data loss from the system   These actions assure that if data were lost from the computer s hard disk  they could be  restored  Another  new  hard disk is normally used for the restoration    It is important that these issues are dealt with prior to the start of production  A functioning  backup system is one of the validation demands the system owner should have in order to  approve of the system   s use in production    Differe
18. as an operating system in a PC  but is far more  complex and accordingly  harder to validate  The same difficulties that may occur in the  validation of a PC operating system can also be found in the validation of the network  operating system  significantly complicating the validation effort     The validation effort can be simplified by following the recommendations of PDA s  committee on vendor evaluation  namely  one can evaluate the network operating system  vendor to assess their technical competence and ability to supply and support the proposed  system  In addition  for widely used programs  and versions   one should perform an  evaluation of the previous uses  For many applications this should indicate that the  program is well functioning and reliable  e g  MS DOS or UNIX      Some suggested validation documents and activities are presented in Table 1  Table 2 lists  some SOPs that should be implemented for a validated network system     Table 1   Suggested Validation Documents Activities    e Network description of all hardware and software  Printout and copies of all system   unique files  such as start up files and settings for the system and login scripts for users    e Drawings  protocol used  drivers  netware  boards    Function tests  such as  communication  checksum tests  or other  of transferred data    stability and stress tests    Security  definition  tests    Test of backup restore  RAID  or other system  SOPs    Evaluation of netware supplier    Evalu
19. ated    does not specify any particular level of validation  it simply means that the  system owner has approved of its fitness for its intended use  Validation of a system should not be  performed simply to please authorities  but to obtain a system that operates as intended   Regulations emphasise that the system should not produce harmful or sub quality products     The following document contains a suggested validation strategy for UNICORN controlled  systems  Following the procedures explicitly will not give any guarantee that a system that  complies with official regulations is obtained  However  if the procedures suggested here are  performed  completed and modified as needed  a validated system can be obtained  We strongly  advise you to be well informed of the regulatory aspects that are related to your product and  process  From a regulatory point of view  the system owner is always responsible for the  performance of his her system  and an established opinion of inspectors is that if written evidence  of an activity cannot be presented  the activity has not been performed  These recommendations  are mainly based on the U S  FDA s Good Manufacturing Practice  GMP   since they are widely  accepted throughout the world     Validation of UNICORN controlled systems can be performed according to the following  illustration  Figure Validation order      Amersham     e Biosciences    Edition AB   January 2004 19    UNICORN 5 0N    Validation order    Design and Requirement
20. ation of hardware suppliers    Network failures   consequences    Storage and access of documentation    Interfaces to other validated systems  verifications    Education of users and network operators    Manuals   hardware  software  and system specific    Other relevant activities documents to verify the function of the network     Table 2  Suggested SOPs    e Backup restore   handling of backup media  frequency  storage  responsibility   generation handling of backups    e How to add new users deletes old  ascertain correct access levels for users    Authorisation to add new users change access levels deletion of users  Documentation   of access level changes for users    Security   routines and responsibility    New hardware  adding new PCs printers and modifications of the net     Access times for the network    Responsibilities for the system    Changes in documentation    Start and stop of the system     Amersham     e Biosciences    Edition AB   January 2004 33    UNICORN 5 0N       Catastrophe routine     including who authorises catastrophe recovery activities   Frequent controls   volume controls  correct access levels for users    New soft and hardware   tests and how to document  approval criteria    Logbook for the system   what to denote and how    Virus controls  frequency and anti virus program to use    Revalidation procedure  frequency  data to use in a revalidation  expected results   Education of users    Manuals   updating  distribution  versions     6 9
21. cations needed to obtain the desired  validation level  This includes not only items mentioned here  but also other relevant  activities  e g   supplier audits  The earlier chapters of this documentation describe the  development instructions and procedures Amersham Biosciences uses to develop and  supply UNICORN  This information is part of a validation procedure of UNICORN  controlled systems  and can be included in the owners validation documentation    As mentioned earlier  tests of the system during its operation will almost certainly not be  all inclusive  This implies that the design of a system is of great importance     6 2 3  Activity Schedule    From the Validation Plan  an Activity Schedule can be extracted  specifying each activity  and responsible person s   The activity schedule can be constructed in different ways  but it  is important to recognise what activities must precede others  A few activities  however   can be performed independently of others  e g   system and general education     General education is dependent mainly on two factors  that the personnel involved in the  development and the handling of the system should have been selected  and the education  should be performed prior to use of the system in production    System education can be divided in two major parts  system specific education and  handling education  the latter being dependent on the existence of an operative system   System specific education can be performed during the IQ and O
22. ch device should be included  Vendor manuals for each piece  of hardware are required  Hardware qualification elements are outlined below     5 3 1  System Description with Schematic Drawings    A schematic representation of the entire system showing the major elements of the system   It should include both process and control system components  as well as any other  computer systems with which the system communicates     5 3 2  Piping  amp  Instrument Drawing    Schematic representation of the equipment in the field  There may be as many of these as  necessary to depict all of the process equipment  They are generally produced early in the  project     Amersham    pa e Y  Biosciences  Edition AB   January 2004 14    UNICORN 5 0N    5 3 3     5 3 4     5 3 5     5 3 6     5 3 7     5 4     5 4 1     5 4 2     Instrument List    A listing of all instruments in the system  including their operating ranges  output signals   selected manufacturer  proposed calibration frequency  accuracy  etc  Each instrument in  the list is uniquely identified and can also be found on the Piping  amp  Instrument drawings     Input Output List    A list of all signals and inputs received by the system as well as all outputs from the  system  Includes communications with other computer systems     Wiring Checks    Verification of the accuracy of cabling and connections to and from all field devices and  I O racks  Also includes verification of cabling between items in the control system and  betwe
23. cribe the physical  hardware  security employed to protect  the system  as well as software security  Verification of security measures is strongly  recommended     Operating Procedures    Standard operating procedures  SOPs  required for manual steps must be completed  These  procedures should include operations performed on a routine basis  as well as procedures  needed for occasional use  i e  calibration preventative maintenance     Amersham  s e Biosciences    Edition AB   January 2004 18    UNICORN 5 0N    6     6 1     VALIDATION OF A UNICORN BASED CHROMATOGRAPHY SYSTEM    Introduction    Validation is a process in which the system owner  who is responsible for the system  performs  actions to determine that a system and process are consistently capable of producing a product  which meets its pre determined specifications and quality attributes  These actions should involve  Design and Requirements analysis  Installation Qualification  Operation Qualification  Method  Development and Verification  Education  and other actions that the system owner finds relevant  in order to allow the system to start  The validation process should end with an approval from the  system owner of all previous activities  meaning that a high degree of assurance  which ensures  that the system is fit for its intended use  has been obtained  After the system owner has approved  the system to start production  or other intended activity   the system can be called validated  The  word    valid
24. e tests should be attached to the revalidation  procedure     e Component tests    e Program test    e Total system test    e Performance test     Additional items should be included if they are relevant to the functionality of the system     6 6  Education    Each user and operator should be educated for his her specific function  This is not only a  regulatory demand  but a way to ensure a system that runs smoothly with a minimum of errors   Most of the mishandling errors are caused by inexperienced users  Education is  of course   especially important for the person s  responsible for handling the operating system  Mistakes in  the operating system can lead to all types of disturbances in the functioning of the system  The  operating system has  by necessity  many powerful commands that can be fatal to the system if  exercised without the knowledge of their effects on UNICORN  This suggests that the person s   responsible for the operating system should have sufficient and updated knowledge in its  handling  and that its use should be minimised  It is also important that the knowledge is current   Education should take place shortly before production start up of the system  If the system is to be  used to produce GMP controlled substances  general GMP education is also required     If the system is modified  users should be informed and educated about the effects of the changes   All education should be documented and maintained properly     6 6 1  System education    Syst
25. em  Installation qualification of software includes verifying that the proper version of the  program has been installed and that the appropriate backup copies exist       The Installation Qualification verifies that the delivered system is complete  and verifies that all  components in the system meet specified requirements    Amersham Biosciences has a unique knowledge of all components in the system  and has  developed a complete package for this purpose  Much time and effort can be spared by using the  Amersham Biosciences Fast Trak Validation Services  More details describing these services are  described in Section 6 9  IQ and OQ Services from Amersham Biosciences Fast Trak Validation     Operational Qualification  OQ     The PDA has defined Operational Qualification of a computerised system as     documented  verification that the system operates in accordance with the computerised systems specification  throughout all anticipated operating ranges  Operational Qualification may be performed on the  integrated system or on each subsystem and includes the identification of all important operating  parameters  their anticipated ranges  appropriate acceptance criteria  and the tests to be performed  to demonstrate that the system meets the acceptance criteria  Operational Qualification also  includes performing specified tests and reporting the results       Amersham Biosciences Fast Trak Validation offers extensive services in this task  described in  Section 6 9  IQ and 
26. em operators require specific education in UNICORN  the computer   s operating  system  and the chromatography part of the system  Relevant and updated knowledge are  essential for the proper functioning of UNICORN and the entire system     Amersham    pa e Y   Biosciences  Edition AB   January 2004 31    UNICORN 5 0N    6 6 2     6 7     6 8     6 8 1     6 8 2     Method education    When the system is designed  a plan for the education of the personnel should be  established  The plan should specify the education requirements for each user function of  the system  Education should be performed previous to the production start of the system   Verifying that all personnel have updated and adequate education for his her function  should be a part of the validation for the system     Validation Approval    As mentioned in 6 1  Introduction  the person responsible for the system should approve of its  fitness for its intended use  This requires checking that everything included in the Validation Plan  has been performed  documented and approved by the personnel responsible for each activity in  accordance with the Activity Schedule    Other things that are relevant to the functionality of the system  but not included in the Validation  Plan  should also be included in the Validation Approval  This may include things that have been  discovered  or things that the persons involved in the validation process find relevant to the  system    All documents generated during the validat
27. en the control system and other computer systems with which it must communicate     Component Qualification    Documentation that all physical components in the control system are installed in  accordance with the vendors recommendations  Includes the satisfactory completion of all  self tests possible on each piece of equipment  To the extent that the computer system can  be tested without application software  that testing should be performed and documented   Issues such as electrical grounding  isolation from power lines  protection from excessive  heat and humidity must be addressed     Calibration    Documented calibration of all field devices from the sensor to the control system  It  includes verification that all locations where a variable is stored  displayed or transmitted  are within the required tolerances  Includes the completion of SOPs for the routine  calibration of the instruments and the initial frequency with which they will be calibrated     Software Development   Verification Phase    Activities associated with the detailed design  preparation and verification of the software to be  utilized on the system     Quality Assurance Methods for Software Development    Copies of procedures utilized by the developers of the program  external and internal   which indicate the software quality assurance measures which are to be followed in the  preparation of the code  Such measures include the use of modular concepts  consistent and  logical use of variable names 
28. es  Edition AB   January 2004    UNICORN 5 0N    6  VALIDATION OF A UNICORN BASED CHROMATOGRAPHY SYSTEM                       19  6 1  INTRODUCTION caridadea eean aea a Eaa a a ariana 19  6 2  DESIGN  VALIDATION PLAN AND ACTIVITY SCHEDULE                i 21  6 2 1  Design and Requirements analysis               e non nnnn non rra naar corr n nr narran rn nn nn nra nenes 21  6 2 2  Validation PDA A A A id A 21  6 2 3  Activity Schedules oinin RO SERRA TALES PRAIA ARA AR 21  6 3  INSTALLATION QUALIFICATION  IQ              iii 26  6 4  OPERATIONAL QUALIFICATION  OQ                  ii 26  6 5  METHOD DEVELOPMENT AND VERIFICATION occcococononcnononononcnononononononononononnnnononononononrnonononenenenon 26  6 5 1  Product Specification iaa iaa 27  6 5 2  Method Development Plutarco 28  6 5 3  Process Optimiza iena 28  6 5 4  Method Construction  nta dai alta edicts heaacedbaacctvebeadates 28  6 5 5  Backup y Restore  rece 29  6 5 6  Verification lalla 30  6 5 7  Operating  INStruCHOAS Aranda 30  6 5 8  R  validationi   lisina ail eat 30  6 6  EDUCATION uniendo gii iaa 31  6 6 1  System education opa illegali 31  6 6 2  Methodieducation saem A sade ew asta a ds STR 32  6 7  VALIDATION APPROVA Li ea 32  6 8  VALIDATION OF PC BASED NETWORKS ccococononononononononononononononononcnnnonnnconononnnrnonnnnnrnnnononnnrnonenonnn 32  6 8 1  Introduction esses anced i A DE ASAS ED aliada 32  6 8 2  Validation Strategy masei naw aata a ii and IR ee aa 32  6 9  INSTALLATION QUALIFICATION A
29. etailed information can be found     The    Backup    activity document should describe the specific steps  and  responsible persons for these   needed to obtain a complete and documented routine   It should also include an official approval  when completed  from the person  responsible for the    Backup    activity     Amersham    PE e Y  Biosciences  Edition AB   January 2004 24    UNICORN 5 0N    Edition AB   January 2004       Select technique    as a suggested first step  would be to determine which  different backup techniques are available  and which one of these is  preferable  considering security  volume  economic  technical aspects and the  effects of a loss of data  These considerations should of course be made in  conjunction with the system owners    expectations of the system     Suggested documentation  A document describing the investigation  considering all aspects involved        Purchase of equipment     refers to the ordering and delivery of the  necessary hard  and software     Suggested documentation  Notes concerning which equipment was ordered   by whom and when  Delivery note s  for the equipment  including  hardware HW  and software SW           Install HW and SW     should describe how  where  when and by whom the  backup system was installed and connected to the system     Suggested documentation  A document describing how the installation was  performed  which directory holds the software  the files in this directory   function of the files  and 
30. for the same period of time as any other regular production document     5 6 2  System Recovery Plan    Focuses on the data recovery and system restart procedures  For example  database  journaling may be used to keep track of all transaction operations that affect the values of  database items  A copy of the software  including essential files  should be kept off line to  be used in disaster recovery  The system recovery plan should address all aspects of  recovery from loss of a hard drive  corruption of a file  or loss of power to the system   Procedures for returning the system to full and proper performance must be in place   Provisions for safeguarding product and essential data must be defined  The validation of  these procedures is recommended     Amersham     e Biosciences    Edition AB   January 2004 17    UNICORN 5 0N    5 6 3     Operating Manuals    Operating manuals should be available to the users of the system at all necessary locations   These manuals must be written at a level such that the actual operators can use them   Verification of user manual correctness can be a concern for systems with many features     Training of Personnel    All users of the system must be trained on the various functions they will be performing   All training should be documented     Support Personnel    A listing of support personnel and their responsibilities and qualifications should be  included as part of the documentation     System Security    The documentation should des
31. how the backup device is connected to the  computer        Select procedure  amp  routines    refers to two things     1  If the system owner has decided that the system should meet high  demands in these respects  a procedure where generations of backups are  created should be established     2  Decide backup and restore routines that will meet the security demands  the system owner has for the system  The routines should involve issues such  as  handling of backup media  storage  accessibility and who decides when   under which circumstances  a restore shall be performed  how frequently  the backup media should be replaced  how the media should be labelled   responsibility for the routines  and other relevant considerations    Suggested documentation  A document describing key issues  and why and  by whom routines and functions were chosen        Test of backup    should verify that the routine works as intended  and that  the contents of a backup can be restored  Observe that the whole routine  should be tested  not only that the files included in the backup can be  restored  Apart from the knowledge that a backup routine works as intended   and the contents of the hard disk can be restored  the test of backup would  also provide knowledge of any obstacles that may occur during the  procedure  and the time it takes to perform a restore to another computer     Suggested Documentation  A protocol describing how the test was  performed with results and evaluation of the test 
32. ibilities for backup and restore   For the restore routine  it is important to state which company function that has the  responsibility for deciding when and under which circumstances a restore shall be  performed     An example of how a backup restore routine can be developed is described under Activity  Schedule  6 2 3      Amersham  s e Biosciences    Edition AB   January 2004 29    UNICORN 5 0N    6 5 6  Verification    As mentioned earlier  the performance of the system is highly dependent on its design  not  only the fluid handling side and the hardware  but also the programmable part of the  computer program  The program should  therefore  be constructed with a functionality  model that minimises the risk of errors caused by poor design    When verification of the computer program and of the chromatographic process have been  performed  according to the Method Development Plan   the method should be approved  by the person designated to be responsible for the system     6 5 7  Operating Instructions    The Operating Instructions are an important part of the validation process  Their main  function can be described as  instructions in how to handle the system when in operation      In the  System Development Life Cycle   the chapter entitled  Operation and  Maintenance    addresses these questions and specifies what should be considered    In cases where the system is intended for production regulated by official rules  these  recommendations should be modified accordi
33. imited  In view of the risk of trademark degeneration  it is  respectfully suggested that authors wishing to use the designations refer to the trademark status at least once in  the article     Amersham and Amersham Biosciences are trademarks of Amersham plc     Any use of UNICORN software is subject to Amersham Biosciences Standard Software End User License  Agreement     All goods and services are sold subject to the terms and conditions of sale of the company within the Amersham  Biosciences group that is available on request        Amersham Biosciences AB 2004     All rights reserved    Amersham Biosciences AB  Bj  rkgatan 30   SE 751 84 Uppsala  Sweden    Amersham Biosciences UK limited  Amersham Place  Little Chalfont  Buckinghamshire   England HP7 9NA    Amersham Biosciences Corporation  800 Centennial Avenue  P O  Box 1327  Piscataway  NJ 08855   USA    Amersham Biosciences Europe GmbH  Munzinger Strasse 9    D 79111 Freiburg   Germany    Amersham Biosciences KK  Sanken Building  3 25 1   Hyakunincho  Shinjuku ku   Tokyo 169 0073  Japan    Amersham    pa e Y  Biosciences  Edition AB   January 2004 35    
34. ion process and the findings of the persons involved in  validating the system should provide information on the suitability of the system to start 1ts  intended production     Validation of PC based Networks    Introduction    The validation of a PC based network is a complex and difficult task  In a regulated  industry  one should consider this complexity prior to connecting a PC to a network  There  is even a risk that the network benefits will not warrant the required validation efforts   There are three reasons for this     1  The published literature only provides an overview of the principles involved in validation  of networks  A great amount of work may be required to interpret and apply these  principles to the individual network     2  Regulators have not yet provided guidance on the requirements for computer networks  and  it is  therefore  difficult to know exactly what is required for regulatory compliance     3  There is a conflict between the  normal  use and handling of a PC network and its use in a  regulated environment  In the latter case  the system must be validated and its use  controlled by SOPs that ensure every change is evaluated prior to its implementation   Situations may occur in which changes considered minor by network operators may be  considered major by QA personnel  In a regulated environment  program version changes   upgrading of hardware  and additions of new functionality are all considered major  changes     These three issues do not i
35. mply that it is impossible to validate a PC network and to  maintain the desired quality level  but rather that the selected technical solution employ a  minimum of hardware and software  The validation effort needed will most likely increase  exponentially with the complexity of the network and the number of programs involved     Validation strategy    The validation of a PC network can be performed by breaking it down into three units   applications  e g   chromatography   network  and interfaces  where data is transferred    Amersham  s e Biosciences    Edition AB   January 2004 32    UNICORN 5 0N    from one unit to another   The same basic principles as those recommended for any  computer system used in a regulated environment should be followed  But it is extremely  important that the interfaces to other validated units on the network are specified and  documented  and any other aspects that affect another unit must also be considered  After  completion of the validation of these three units  the entire PC network is validated as a  whole by testing it under  normal  situations as well as performing stress tests to verify the  correct behaviour of the system under different situations  Stress testing may include  communication failure simulation and security challenges     PC networks require a network operating system which handles the network  communications  file management  user access  etc  The operating system has control over  the network in much the same manner 
36. ngly    Observe that these recommendations are not    batch specific     which means that they do  not specify what procedures  documentation  etc  are required for such production    The Operating Instructions should contain the following instructions and documentation     Routines for backup and restore    Adding   modifying   deleting users   Responsibilities for the system    Functions in the system    Organisation around the system    Security  routines and responsibilities     Change control procedures    Log book for the system    External contacts and companies  suppliers    User education    User manuals    Frequency of revalidation    System maintenance  schedule and procedures    Cleaning instructions    Calibration schedule and procedures    Other relevant instructions for the operation of the system     The Operating Instructions are a part of the validation and specify how the system should  be handled when in operation  The Operating Instructions should be updated whenever any  system related changes are made  Such changes shall also be recorded  dated  and signed in  the system logbook  in accordance with the Change Control Procedures    An important part of the revalidation is to verify that the Operating Instructions are  updated and handled correctly     6 5 8  Revalidation    The U S  FDA recommends that all computerised systems are frequently revalidated and  that there is a specific revalidation procedure for each system  Since there is no  recommended f
37. nt media  storing techniques  for the contents of the computer   s hard disk can be  used  but magnetic tapes in cassettes are the most common  Magnetic tapes are  inexpensive  have a large storage capacity  and can be overwritten with new data when so  desired  One disadvantage is that they are quite time consuming to use  therefore many  systems use automatic routines  which perform backups at night    When a backup routine is developed  generations of backups should be considered  since  not all problems that may occur in a system  and originate from the hard disk  are  discovered instantly    If magnetic tapes are used  they should be replaced at timely intervals  according to the  supplier   s specification    Backup routines should be tested in order to verify that the desired files really are restored  from the media when the restore routine is used  Verification of this should be included in  the validation of the system    Storage and handling of the media containing backups should also be considered when a  backup routine is constructed  To prevent simultaneous loss of both backup media and  contents on the computers hard drive  they should be stored in different locations     When designing routines for the backup  remember that the media with backups may hold  vital confidential information about your production process     Operating procedures describing how a restore is performed should be developed and  tested  There should also be documents stating the respons
38. nufacturing Practices  Good Laboratory  Practices  and Good Clinical Practices     ty lo    Dr  Sandy Weinberg       y Amersham    o e Y  Biosciences  Edition AB   January 2004 5    UNICORN 5 0N    Amersham    e Y  Biosciences  Edition AB   January 2004 6    UNICORN 5 0N    3  AMERSHAM BIOSCIENCES QUALITY MANAGEMENT SYSTEM  3 1  Introduction    Amersham Biosciences    quality management system  BMI  Business Management Information    is based on a process and system approach as described in the Protein Separations Quality  Manual  It encompasses the steering structures and procedures needed to achieve the business  objectives     3 2  Protein Separations Quality Policy    The Quality System should support the strategy of Protein Separations by assuring quality through  active management of the following     e Identification and documentation of customer needs    e Development  manufacturing and delivery of products and services to meet or exceed those  needs consistently    e Feedback from customer assessment leading to improvement in performance for Protein  Separations  minimising cost and complaints     3 3  ISO Certification    ISO 9000 is an internationally accepted series of quality management standards  Certification  requires rigorous auditing by an independent accredited agency which examines the quality  documentation system and confirms that the organisation actually operates in accordance with  stipulated principles and instructions     Amersham Biosciences first 
39. od Development and Verification as part of Validation Plan                   Product Specification 54 Design and Requirements Analysis     2 1    Method Development Plan Lo Validation Plan    y    Activity Schedule    y    Installation  Qualification    y    Operation  Qualification    q y    Verification Method Development    and Verification    y y    Operating Instructions 5  Method education    L   y                                  d          Process Optimisation and  Method Construction i                  3  4             D            Backup   Restore                                           uoneonpa   esjaueb   uoneonpa wajs  s    V9 9                5 8            Revalidation Procedure Validation Approval                            Product Specification    The first step in the development of a new process is to determine process goals   Requirements for product purity  activity  and quantity should be specified  Economic  considerations can also be included in the Product Specification     Amersham  s e Biosciences    Edition AB   January 2004 27    UNICORN 5 0N    6 5 2  Method Development Plan    The activities needed to obtain a method  which complies with the Product Specification   should be specified in the Method Development Plan  The plan should also describe which  documentation should result from the activities  Responsibilities for each activity should be  stated     6 5 3  Process Optimization    Developing a process to optimize yield is often a complex
40. ontrol system to confirm their acceptability   i e   cleaning  data reduction  etc     5 5 4  Additional Software Verification Requirements    Additional testing is required to establish that other software features are correct and  function as desired  Examples of the types of additional software capabilities  which must  be validated include  verification of security measures  confirmation of communication  capabilities with other computer systems  verification of data archive systems  and protocol  management  In general  all the features and capabilities of the computerised system must  be validated     5 6  Operational Phase    The procedures and systems needed to ensure the acceptability of the system over time should be  inspected at the time of system start up     5 6 1  Change Control    Change control procedures must be developed whereby changes in the process  process  equipment  software and computer hardware may be evaluated  approved and documented   As necessary  additional qualification and or validation may be needed to evaluate a  change  The procedure should allow for both planned and emergency changes to the  system  Emergency change methods are needed when situations requiring immediate  action to protect personnel  equipment or product are encountered  Change control  procedures must include provision for the updating of pertinent documentation on the  system including many of the elements of this document  Records of changes to the system  must be kept 
41. requency for revalidation this has to be decided by the system owner   Revalidation does not mean that the system has to be validated all over again  but rather  that there should be a specific procedure that ensures the system owner that the system  works as intended after a specific period of time    Accordingly  it is recommended that the system owner develop a Standard Operating  Procedure that describes the frequency and protocols for revalidation    Observe that calibrations  which should be carried out frequently  are not revalidation     Amersham  s e Biosciences    Edition AB   January 2004 30    UNICORN 5 0N    Wherever applicable  the revalidation procedure should contain specific test data sets and  procedures  which when processed in the system should give specified results that are to be  compared to those expected    A suggested revalidation procedure cannot be specified here since it is site dependent   however  the following items should be included     Verification of the following documentation    e Log book    e Updated user manuals and SOPs for all activities   e Documents from the system validation     Verification that the following has been carried out in accordance with SOPs   System changes  according to change control procedures   Log book entries    Security procedures    Calibrations    Sanitation s    Errors and disturbances reports    Education    Service and maintenance    Backup    Adding deleting users     System test procedure  data for thes
42. rols   KTA    BioProcess     OligoPilot     and OligoProcess    systems  It also suggests  a validation order and documentation that may be generated through the different steps in the  validation procedure  Installation Qualification and Operational Qualification services available  through Amersham Biosciences Fast Trak Validation are described in section 6 9     A standardised source code escrow agreement for UNICORN can be ordered through Amersham  Biosciences Fast Trak Validation     INTRODUCTION TO UNICORN VALIDATION    General UNICORN information    Amersham Biosciences UNICORN system affords state of the art control over Amersham  Biosciences chromatography systems  providing a level of sophistication and refinement not  available in other competitive chromatography control systems     The configurable nature of UNICORN allows considerable variation in systems to meet the  requirements of an individual customer  These activities involve the participation of both  Amersham Biosciences and the system   s owner from the start of the purchasing activity through  system start up at the owner s location     Each UNICORN system is delivered with the same software  but many of its capabilities can only  be accessed if the particular system itself is equipped for that specific function  The sophistication  of the software allows even the most complex chromatographic separations to be implemented  since they can be assembled from software components included with each UNICORN  
43. s Analysis  2 1       Validation Plan    y    Activity Schedule             y   w          Installation  Qualification       Operation  Qualification               Method Development  and Verification             y    Method education    y    Validation Approval    uoljeonpe   eJauab   uoljeonpe wa sAs ta                            The figure    Validation order    illustrates that validation is a process with components  and not just  a task that has to be carried out before a system 1s put into production     Amersham    pa e Y  Biosciences  Edition AB   January 2004 20    UNICORN 5 0N    6 2  Design  Validation Plan and Activity Schedule    6 2 1  Design and Requirements analysis    System design is vital to its function  Amersham Biosciences provides design assistance to  its customers and most systems delivered are designed in accordance with customer  demands    The design phase should not only involve the construction of the chromatography unit  but  also take into consideration the intended use of the system  The intended use will dictate  the required level of validation  For example  the requirement for production of a  therapeutic product is quite stringent     6 2 2  Validation Plan    A Validation Plan should include all components required to obtain the desired validation  level  The plan and specified activities are fundamental in the validation of the system  and  should be approved by the system owner    The Validation Plan should include all tests and verifi
44. s utilises structured and documented procedures to provide customers with  high quality products  To comply with this  customer expectation  opinions and other relevant  information are gathered together with Amersham Biosciences development principles and  technical modifications  These are considered when UNICORN software is developed     Adherence to Amersham Biosciences procedures is verified throughout all phases of product  development     4 2  Development model    The procedure for product development defines the phases  main activities and responsibilities   reviews and phase exits to be performed  This is visualised in the Figure    Development  D   project        Amersham    pa e Y  Biosciences  Edition AB   January 2004 9    UNICORN 5 0N    Descrhe market  needsin PDR    Estimate cost end of  Definition Phase       Edition AB   January 2004    Development  D  project              Phase 1 Phase 3 Phase 4 Phase 5  Definition Detailed Planning Development Market Readiness Launch  Preparation                       Business opportunity Team building and Design Registration and Launch support  detailed planning   General approach legislation    Software  local      Hardware  local     Available technology System requirements in   Chemistry  local     E Launch preparation    System verification plan Manufacturing  System integration and support  verification Manufacturing scale    Product definition in atch    PTD       System   product design  inDD  Manufacturing process
45. system   quality begins at design level  We suggest   as earlier mentioned  that the system is handled in accordance with PMA s  System Development  Life Cycle  when your own programs and methods are developed  Amersham Biosciences Fast  Trak Validation offers a large number of services to support customers in these matters    To verify that a developed method works as intended  we suggest that you start with a Product  Specification describing the aim of the process  After this  a Method Development Plan should be  established and include details of the activities needed to fulfil the Product Specification    The Process Optimisation and Method Construction are integrated activities intended to develop a  method  which chemically fulfils the Product Specification    The procedure should continue with a Verification in which the earlier activities are verified and  approved    The last steps in the Method Development and Verification are to establish Operating Instructions  and a Revalidation Procedure  The Operating Instructions should be operating procedures for  every function in the system and should describe the responsibilities for each function of the  system  who is responsible for what     The Revalidation Procedure should describe what should be controlled  tested and verified  regularly  and the criteria for the approval of a revalidation    This can graphically be presented as shown in Figure Method Development and Verification as  part of Validation Plan     Meth
46. te the  validation effort  For comparison to the life cycle diagram in the PMA concept paper  the  requirements have been separated into major headings  which correspond to the major segments  of the PMA life cycle  The following list is not intended to be all inclusive  Depending on the  application and sophistication of the system  the details of any individual system may be  significantly different from that described herein     5 2  Design    Specification Phase  This portion of the project establishes the groundwork for the entire effort     5 2 1  Functional Requirements    A description of the functions which the computerised system must provide  It defines the  scope of the hardware and software required to complete the project  It is essentially a  shopping list indicating the desired features of the completed system  It is sufficiently  detailed to establish the design while allowing for flexibility in the design at the same time     5 2 2  System Specification    A detailed compilation of the system as designed to meet the elements of the Functional  Requirements  It identifies specific hardware features  CPU  printers  CRTs  storage  devices  UPSs  and their overall arrangement  and an overview of software considerations   report formats  levels of alarms  scan time  menus  etc       5 3  Hardware Installation  amp  Qualification Phase    This activity includes documentation and verification of the hardware required  Hardware  configuration   specifications for ea
47. tion refers to the Installation Qualification and Operational Qualification  IQ and  OQ  for the system  These document templates can be ordered separately from  Amersham Biosciences Fast Trak Validation by the customer  but are not a part of the  documentation delivered with the system     Method refers to the customer   s method development and other relevant procedures  i e   education of users   These procedures are described in more detail in the Section  Validation of a UNICORN based Chromatography System     Protein Separations is the knowledge and activities needed to optimize the process as the  choice of chemicals  media  product materials  buffers  etc     Amersham    o e Y  Biosciences  Edition AB   January 2004 2    UNICORN 5 0N    2 2  Version numbering    When UNICORN software is changed modified  the numbering system is used to indicate which  degree of modification has been performed  The following text describes the principles used     The version number used consists of 3 digits and is written X YZ  Example  4 12     X     New version  e new operating system  e major new functionality    Y Update    e adaptations for new hardware components  e minor new functionality    e correction of software errors  e no new functionality  specifications not extended  e software manual not affected  Bug fixes are separate from updates  new functionality and new version releases     When X is incremented  Y and Z are set to zero  When Y is incremented  Z is set to zero   
48. ware are combined  and verification  of the combination is performed  Usually this verification is performed in a modular fashion  but  eventually all parts of the system must be placed into service  Verification reports are prepared for  all of the testing performed in this phase  The results of all the testing done at this phase are  included in a formal verification report     5 5 1  Module Level Verification    Testing of individual modules to demonstrate their adherence to the specifications   Verification at this level consists of individual functions  e g  alarms  report formats  screen  displays  data transmission  Testing of individual modules in a distributed control system is  an example of this type of verification     5 5 2  Program Level Verification    Program Level Verification is testing of individual programs to confirm their conformance  to specifications  Testing at this level is performed in one or more of the following ways     Simulation    Simulation is the use of simulated inputs to the control system to confirm that the  computer system responds in the desired way to each input  The inputs should be  both in accordance with the routine process  uneventful   to confirm proper  sequence  or outside the norm  eventful   to confirm the appropriate response to  anticipated process or system upsets   The simulation trial confirms the  acceptability of the computer system  Simulation should be performed on every  module which will be utilised on the system 
    
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