Manufacturing execution system for validation, quality and risk assessment and monitoring of pharmaceutical manufacturing processes

• US 7,379,784 B2
• Filed: 10/10/2006
• Issued: 05/27/2008
• Est. Priority Date: 05/06/2004
• Status: Active Grant

• Current Assignee: SMP Logic Systems LLC
• Original Assignee: SMP Logic Systems LLC
• Inventors: Popp, Shane M.
• Primary Examiner(s): VON BUHR, MARIA N
• Application Number:
  US11/545,366
• Publication Number:
  US 20070032897A1
• Time in Patent Office: 595 Days
• Field of Search: 700108-111, 700239-244, 700265-274, 700/285, 702182-187
• US Class Current: 700/110
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 2219/11 Plc I-O input output
• CPC Class Codes: G05B 2219/1112 Bit addressing, handling
• CPC Class Codes: G05B 2219/31277 Dispatching rules, shortest travel time or bidding based to reduce empty travel
• CPC Class Codes: G05B 2219/32177 Computer assisted quality surveyance, caq
• CPC Class Codes: G05B 2223/02 Indirect monitoring, e.g. monitoring production to detect faults of a system
• CPC Class Codes: G05B 23/0224 Process history based detection method, e.g. whereby history implies the availability of large amounts of data
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 50/04 Manufacturing
• CPC Class Codes: G16H 20/10 relating to drugs or medications, e.g. for ensuring correct administration to patients
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/30 Computing systems specially adapted for manufacturing
• CPC Class Codes: Y02P 90/80 Management or planning
• CPC Class Codes: Y10T 436/2575 Volumetric liquid transfer

Abstract

Manufacturing execution systems relating to methods, systems, and software program for validation of pharmaceutical manufacturing processes and quality assurance process are described and disclosed herein. Consequently, the methods provide a means to perform validation on an integrated level whereby the quality control unit can ensure data and product integrity and minimize cost.

Claims

1. A method of monitoring an acceptance criteria of a pharmaceutical manufacturing operational unit said method comprising,

a) monitoring data generated by an operational unit during pharmaceutical manufacture;

b) maintaining the data over time to provide a historical record;

c) analyzing the historical record to provide a comparative analysis against an acceptance criteria;

d) taking corrective action during pharmaceutical manufacture to obviate a rejection against the acceptance criteria whereby said corrective action comprises modifying said pharmaceutical manufacture.

2. The method of claim 1, wherein the operational unit is integrated into a pharmaceutical manufacturing software system using at least a time-stamped audit trail.

3. The method of claim 1, wherein the operational unit is integrated into a pharmaceutical manufacturing hardware system using at least a pure water system.

4. The method of claim 1, whereby the monitoring occurs at initial process.

5. The method of claim 1, whereby the monitoring occurs at end process.

6. The method of claim 1, wherein the monitoring is part of routine maintenance to assure conformance with pharmaceutical manufacturing quality control.

7. The method of claim 1, wherein the data is generated by an analysis selected from the group consisting of failure, boundary value, branch, block check, control flow, failure modes and effects, and path.

8. The operational unit of claim 1, wherein the operational unit is selected from the group consisting of motors, drives, compressed air systems, HVAC, boilers, and back-up generators.

9. A method of monitoring an acceptance criteria of a cell culture system said method comprising,

a) monitoring data generated by a cell culture system during pharmaceutical manufacture;

b) maintaining the data over time to provide a historical record;

c) analyzing the historical record to provide a comparative analysis against an acceptance criteria;

d) taking corrective action during pharmaceutical manufacture to obviate a rejection against the acceptance criteria whereby said corrective action comprises modifying said pharmaceutical manufacture.

10. The method of claim 9, wherein the cell culture system is integrated into a pharmaceutical manufacturing software system using at least a data security system.

11. The method of claim 9, wherein the cell culture system is integrated into a pharmaceutical manufacturing hardware system using at least a bio-reactor.

12. The method of claim 9, whereby the monitoring occurs at initial process.

13. The method of claim 9, whereby the monitoring occurs at end process.

14. The method of claim 9, wherein the monitoring is part of routine maintenance to assure conformance with pharmaceutical manufacturing quality control.

15. The method of claim 9, wherein the data is generated by an analysis selected from the group consisting of failure, boundary value, branch, block check, control flow, failure modes and effects, and path.

16. A method of monitoring an acceptance criteria of a pharmaceutical manufacturing field instrumentation component said method comprising,

a) monitoring data generated by a field instrumentation component during pharmaceutical manufacture;

b) maintaining the data over time to provide a historical record;

c) analyzing the historical record to provide a comparative analysis against an acceptance criteria;

d) taking corrective action during pharmaceutical manufacture to obviate a rejection against the acceptance criteria whereby said corrective action comprises modifying said pharmaceutical manufacture.

17. The method of claim 16, wherein the field instrumentation component is integrated into a pharmaceutical manufacturing software system using at least a user-independent audit trail.

18. The method of claim 16, wherein the field instrumentation component is integrated into a pharmaceutical manufacturing hardware system using at least a blender.

19. The method of claim 16, whereby the monitoring occurs at initial process.

20. The method of claim 16, whereby the monitoring occurs at end process.

21. The method of claim 16, wherein the monitoring is part of routine maintenance to assure conformance with pharmaceutical manufacturing quality control.

22. The method of claim 16, wherein the data is generated by an analysis selected from the group consisting of failure, boundary value, branch, block check, control flow, failure modes and effects, and path.

23. The field instrumentation component of claim 16, wherein the field instrumentation component is selected from the group consisting of calibration tools, flow meters, intrinsic safety devices, leveling components, weighting components, process analyzers, thermometers, and valves.