I. TUJUAN
1.1. Membuktikan dan mendokumentasikan bahwa instalasi teknis telah memenuhi
persyaratan untuk digunakan dalam proses produksi, pengemasan atau analisa,
dapat beroperasi dengan benar dalam toleransi yang telah ditentukan dan
memberikan hasil yang memenuhi persyaratan.
1.2. Mengatur pelaksanaan kualifikasi secara umum.
III. DEFINISI
Istilah Definisi
Kualifikasi Kegiatan pembuktian terdokumentasi yang menunjukkan bahwa unit/
sistem yang digunakan untuk proses pembuatan dan pengujian obat
terpasang dengan benar, dapat beroperasi dengan baik sesuai regulasi
GMP dalam rentang toleransi tertentu serta hasil yang konsisten
sesuai dengan yang diharapkan.
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Kualifikasi merupakan bagian dari validasi namun secara umum
tidak termasuk dalam validasi proses.
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Kualifikasi bisa menggantikan kegiatan commissioning, Factory
Acceptance Test (FAT), dan Site Acceptance Test (SAT).
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Instalasi Instalasi teknis adalah ruangan, mesin, peralatan, alat bantu, utilitas,
teknis sistem penyediaan dan pembuangan yang digunakan untuk produksi,
pengemasan dan analisa obat jadi, produk antara dan bahan awal.
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Istilah Definisi
Melakukan sterilasi (misal: autoclave)
Mengontrol atau menyediakan informasi yang berkaitan dengan
penerimaan hasil pengujian produk (misal: instrumen analisa)
Fasilitas, sistem atau mesin/ alat dengan direct impact terhadap kualitas
produk harus dikualifikasi.
Sistem yang Sistem penunjang dari sistem direct contact/ impact yang tidak
mempunyai mempengaruhi kualitas, keamanan, dan khasiat produk. Contoh sistem
pengaruh tak pengaruh tak langsung adalah pendingin air (chiller), pemanas air
langsung/ (boiler) dan emergency power. Contoh sistem yang tidak berpengaruh
tak adalah pengolahan air limbah.
berpengaruh Fasilitas, sistem atau mesin/ alat indirect impact/ no impact tidak perlu
(indirect/ no dikualifikasi.
impact)
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Advisor
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operator, teknisi, analis, atau inspektor dari departemen yang terkait.
Fungsi ini dijalankan oleh Operations Director. Meskipun tidak terlibat
secara langsung namun persetujuan dari Advisor diperlukan sebagai
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kelengkapan dokumen kualifikasi.
Bila menyangkut instalasi teknis milik pihak ketiga, maka wakil yang
ditunjuk dari pihak ketiga termasuk dalam tim kualifikasi sebagai
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Advisor.
Secara garis besar, tugas dari masing-masing fungsi dapat dijabarkan dalam tabel di
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bawah ini:
Validasi
IQ OQ PQ Validasi
Proses
Protokol Protokol Protokol Pengemasan
Fungsi Protocol
dan dan dan Protocol
dan
Report Report Report dan Report
Report
Quality & Compliance (Q&C) X* X* X* X X
Manufacturing X X X X X
SMP/TT** X
Global
Engineering/Operations/Process X X X
Engineering**
* Penandatangan internal J&J manufacturing, dan Q&C. Eksternal J&J, tandatangan Q&C bukan
mandatori.
**Tergantung pada struktur organisasi regional, kelompok fungsional lainnya mungkin bertanggung
jawab atas aktivitas ini.
V. PERSYARATAN
Personil yang melakukan (SOP-019469) sebagaimana diuraikan dalam prosedur ini
harus menyelesaikan pelatihan mengenai prosedur ini, dan pelatihan personil tersebut
harus didokumentasikan sebelum melaksanakan prosedur tersebut.
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6.2. Rekualifikasi
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Rekualifikasi dilakukan untuk memastikan dan memperbaharui status kualifikasi.
Jenis rekualifikasi ada 2 macam:
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6.2.1. Periodic Review
Dilakukan periodic review untuk memastikan bahwa status kualifikasi
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6.4.2. Kualifikasi sistem tata udara (AHU/ HVAC), LAF (Laminar Airflow) dan
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sistem pengumpul debu (Dust Collector)
Point-point yang dapat dipertimbangkan:
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setiap 3 bulan)
→ Pengambilan sampel bisa ditingkatkan frekuensinya terkait
dengan musim terutama jika musim tersebut mempengaruhi
kualitas sumber air (potable water)
→ Alert level ditetapkan sebesar setengah dari action limit untuk
pemantauan mikrobiologi & Total Organic Carbon (TOC)
→ Rencana pengambilan sampel untuk pemeriksaan rutin ditetapkan
berdasarkan hasil pemeriksaan fase 3, termasuk penetapan alert
dan action limit serta frekuensi pembersihan dan sanitasi
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6.4.4. Kualifikasi sistem utilitas selain sistem air (misal: sistem udara tekan-
compressed air system dan sistem uap-steam)
Point-point yang dapat dipertimbangkan:
Uji fisika-kimiawi (dilakukan minimal 3 hari berturut-turut)
Uji mikrobiologi (dilakukan minimal 3 hari berturut-turut)
Parameter proses yang dapat mempengaruhi kualitas (misal: suhu,
tekanan, laju alir)
Integrity test untuk microbe-retaining filter (0.45 µm)
Microbe retention rate atau microbe reduction rate untuk instalasi
pengurang mikroba (misal: lampu UV, ozonisasi). Hasil uji dari
supplier juga dapat digunakan
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6.4.5. Kualifikasi peralatan uji mikrobiologi dan uji kimia
Alat-alat yang perlu dikualifikasi diantaranya autoclave, inkubator,
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waterbath, LAF unit, dll.
Point-point yang dapat dipertimbangkan:
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Uji fungsi
Uji proses control
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6.6.1. Fasilitas, sistem, dan peralatan yang digunakan dalam proses produksi,
pengemasan dan pengujian harus dikualifikasi. Untuk fasilitas atau alat
yang sudah ada dan belum terkualifikasi, dokumen dan data penunjang
yang menunjukkan alat tersebut dapat bekerja dengan baik harus tersedia.
Fasilitas, sistem, dan peralatan tersebut dapat digunakan tetapi
kualifikasinya harus segera dilakukan.
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6.6.5. Impact Assessment dari sebuah project disusun sebelum kegiatan instalasi
dilakukan dan dinamakan Design Review. Hal ini dimaksudkan memeriksa
kesalahan desain dengan dampak langsung pada kualitas produk sebelum
unit/ system berada pada tahap instalasi.
6.6.6. Laporan kualifikasi terdiri dari DQ, IQ, OQ, dan PQ. Khusus untuk
equipment baru/ modifikasi harus merujuk kepada URS pada saat
melakukan Design Qualification. Untuk dapat melanjutkan ke tahapan
berikutnya, setiap laporan terlebih dahulu di tandatangani oleh tim
kualifikasi. Namun, bila dalam hal ini kebutuhan terhadap unit/ system
tersebut tinggi, maka test plan results dapat dipergunakan sebagai bukti
untuk bisa melanjutkan proses kualifikasi ke tahapan berikutnya tanpa
menunggu laporan kualifikasi dengan pertimbangan tidak ada
penyimpangan selama kualifikasi berlangsung.
yang tidak memenuhi kriteria masih dapat dianggap salah satu dari
rangkaian pengujian jika dalam pengujian tersebut terjadi:
Kesalahan operator
Kesalahan teknis
Hasil pengujian tidak sah (karena kesalahan operator atau kerusakan
alat)
Perubahan rencana
Pengujian tambahan harus dilakukan untuk menggantikan pengujian yang
tidak memenuhi kriteria.
Jika terdapat penemuan yang tidak dapat diterima, maka:
Kerusakan harus dihilangkan (contoh: dengan mengganti
peralatan atau proses) dan kualifikasi yang bersangkutan
diulang kembali
Proses kualifikasi dihentikan
Pembatasan untuk operasi selanjutnya harus ditetapkan
Rekomendasi untuk perbaikan kualitas dapat diberikan dalam
laporan kualifikasi. Status pengerjaan rekomendasi sekurang-
kurangnya 3 bulan sekali
6.6.9. Sistem yang telah terkualifikasi tidak memerlukan penandaan/ label. Status
terbaru dari suatu sistem dapat dilihat di dalam Validation Master Plan
edisi terbaru. Jika terdapat sistem yang harus dikualifikasi/ direkualifikasi
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6.6.10. Rencana kualifikasi dan laporan kualifikasi yang asli disimpan di lemari
Kualifikasi selama minimum 10 tahun setelah tanggal berlaku dokumen
tersebut. Sedangkan salinan dari rencana kualifikasi dan laporan
kualifikasi didistribusikan kepada departemen terkait.
VII. REFERENSI
7.1. SOP-019435 Document Control Process
Monitoring Number of Microorganism in Cleanliness Class D
7.2.
7.3.
SOP-019574
SOP-020104
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HEPA & Cleanliness Class E
Cleanliness Classes in PT. IHI
7.4. FM-012097 GxP Assessment Matrix
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7.5. FM-021680 User Requirement Specification
7.6. FM-023883 Qualification Trial
7.7. FM-023884 Periodic Review
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I. PURPOSE
1.1. Proving and documenting that the technical installation meets the requirements for
use in the production process, packaging or analysis, can operate properly within
the defined tolerances and deliver results that meet the requirements.
1.2. Manage the implementation of the qualifications in general.
II. SCOPE
2.1. This SOP applicable to all qualification activities at PT. IHI which have a direct
impact on product quality.
III. DEFINITION
Terms Definition
Qualification Activities documented evidence which shows that the unit/ system
used for the production process and testing of drugs is properly
installed, can operate properly according to regulations of GMP in
a certain tolerance range and the results are consistent with the
expected
Qualification is part of validation, but generally not included in the
validation process
Qualifications can replace Commissioning activities, Factory
Technical
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Acceptance Test (FAT) and Site Acceptance Test (SAT)
Technical installations consist of rooms, machines, equipment, tools,
Installations utilities, supply and disposal systems used for production, packaging
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and finished product analysis, intermediate products and raw
materials.
Qualification Qualification plan contain a description of the technical installations,
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Plan the responsibilities and duties of the qualification teams, risk analysis,
tests to be carried out and its terms.
Qualification Qualification report is a compilation and evaluation of test results and
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Terms Definition
The system has Supporting system of the system of direct contact/ impact that does
an indirect not affect the quality, safety, and efficacy of the products. Examples of
effect/ no indirect influence system is a water cooler (chiller), water heater
effect (boiler) and emergency power. Examples are systems that do not
(indirect/ no affect wastewater treatment. Facilities, systems or machinery/ indirect
impact) impact/ no impact does not need to be qualified.
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Role Responsibilities
acceptance criteria of a qualification
Ensuring associated with GMP requirements are met in the
implementation of qualification
Responsible for the fulfilment of the qualification standards of
technical installations which have been determined during the
qualification process
Executor The executor of the qualification process. During the implementation
of the qualification, executor who qualify should be given training and
conduct the procedure based on qualification plan. The function of
executor is run by supervisors, operators, technicians, analysts, or
inspectors from the relevant department.
Advisor This function is executed by the Operations Director. Although not
directly involved, but approval from the Advisor required as a
qualification document.
When it comes to technical installations belonging to third parties, the
appointed representative of the third party included in the
qualification team as Advisor.
In outline, the task of each function can be described in the table below:
IQ ed OQ
Protoc Protoc Protoc
PQ
Process Packaging
Validation Validation
Function Protocol Protocol
ol and ol and ol and
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and and
Report Report Report
Report Report
Quality & Compliance (Q&C) X* X* X* X X
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Manufacturing X X X X X
SMP/TT** X
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Global
Engineering/Operations/Proce X X X
ss Engineering**
* Internal J&J manufacturing site, Q&C approves. External J&J site, Q&C approval not
mandatory.
** Depending on the regional organizational structure, other functional groups may be
responsible for these activities.
V. REQUIREMENTS
Personnel performing (SOP-019469) as outlined in this procedure must be trained on
this SOP, and their training must be documented prior to executing this procedure.
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Design Qualification can be used to indicate that the clause of the design of
the facilities, systems, utilities and equipment have met a user requirement
and in accordance with the requirements prior to installation/ construction.
For simple equipment, DQ can be an examination of the specifications that
have been approved or complete the purchase document that has been
approved. As for equipment’s that are more complex DQ can be an
examination of the suitability of the content of the following documents:
Drawing approved
The position of the equipment/ machine in the room
PID
Wiring diagram
Function or usefulness
Workflow/ flow pattern
Machine specifications/ material
If this information is also summarized in URS, the DQ can be simplified into
URS examination, then these activities called by Design Review. To
requalification due to changes to the technical installations, DQ is done by
checking the change control records are valid.
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to prove and document that all parameters affecting the quality of the
product meets the requirements in accordance with its function in all the
range that has been defined. OQ can be performed in a whole system or on a
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6.2. Requalification
Requalification is conducted to ensure the qualification and status updates.
Requalification types there are 2 kinds:
6.2.1. Periodic Review
In this requalification, performed periodic review to ensure that the
qualification status of the unit/ system is still valid. Furthermore, the
assessment carried out to assess any changes, deviations and maintenance
actions are carried out on the unit/ system does not affect the status of
qualifications and produce products in accordance with a predetermined
quality.
The data already available (e.g., calibration and monitoring) can be used and
the scope of the examination can be reduced. In the periodic requalification,
unit/ system already qualified status and can still operate. The process of
deliverance (release) of the product are not affected by the requalification
process if there are not deviation that affect the quality of the product.
Requalification is performed at intervals as follows:
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Type of Technical Installations Period Tolerances
Technical installations that affect the
1 year 1 month
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sterility (eg, sterilizers, autoclaves, ovens)
Cleanliness area class E 3 years 3 months
Purified water treatment unit 3 years 3 months
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6.3. Flowcharts
Process flow of the qualification process in general can be found in appendix 1.
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6.4.2. Qualification for the HVAC system (AHU/ HVAC), LAF (Laminar Airflow)
and a dust collecting system (Dust Collector)
Points to consider:
Filter AHU (specifications, quantity, pressure difference of filter)
Ambient air emissions
Leakage test of filter (integrity test)
The pattern of air flow
The flow rate of air
Control Equipment
Monitoring procedures
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Vent filter
Test process control
Sanitation including passivation and periodic sanitation
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6.4.4. Qualification system utility other than the water system (e.g. compressed air
system-compressed water-steam system and steam system)
Points to consider:
Physics-chemical test (minimum of 3 consecutive days)
Microbiology test (minimum of 3 consecutive days)
The process parameters that can affect the quality (e.g., temperature,
pressure, flow rate)
Integrity test for microbe-retaining filter (0.45 m)
Microbe retention rate or microbe reduction rate for the installation
of a microbial reducers (e.g., UV light, ozonation). Test results from
a supplier may also be used
Process control test
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Testing conditions
Test method
The acceptance criteria (acceptance criteria)
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6.6.1. Facilities, systems, and equipment which used in the production process,
packaging and testing must be conducted qualification. For facilities or tools
that already exist and are not currently qualified, documents and supporting
data indicate that the tool can work well should be available. Facilities,
systems, and equipment can be used but the qualification should be
conducted immediately.
6.6.3. Qualification plan and report made by the Qualification Officer and
reviewed by a qualification officer. Numbering documents refers to SOP-
019435 about the numbering system qualification and validation documents.
6.6.4. Checking plan and reports can be taken from the qualifications undertaken
by the vendor with adaptation according to the current standards if
necessary. Checking plans and reports must be authorized by the user of the
system (User) through the general format of qualification plans and reports
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contained in the FM-021681, FM-023885, FM-023886, FM-021682, FM-
023887, FM-023888.
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6.6.5. The Impact Assessment of a project will be performed prior to installation
activities are carried out and called as Design Review. It has purpose to
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uncover design errors with direct impact on product quality before unit/
system is at the installation phase.
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6.6.6. The qualification report consists of DQ, IQ, OQ, and PQ. Specifically, for
new equipment or modifications must refer to the URS when conduct the
Design of Qualification. To be able to proceed to the next stage, each report
must sign by the qualification team before. However, if in this case it is
necessary for the unit / system very high, then the results of the plan test can
be used as evidence to be able to carry out the next process without waiting
for the report considering that there are no deviations during the
qualification.
6.6.7. Coordinators organize testing activity. All test reports must be signed and
evaluated by the operator or supervisor of the department concerned before
it is sent to the coordinator.
Test activities / test plan results shall be signed by the Owner of the unit /
system and Quality Unit before qualification continues to the next stage.
This approach can only be applied under special condition where the unit
/system is urgently required to be used.
6.6.8. If qualifications require multiple consecutive testing, testing that do not meet
the criteria can still be considered valid in a test of series, if your test case:
Operator error
Technical error
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6.6.9. The system that has been qualified does not require marking/ labelling. The
latest status of a system can be seen in the latest edition of Validation Master
Plan. If there is a system that must be qualification/ requalification, then
Qualification Officer will provide preliminary information to the Technical
System Owner prior to the implementation of the qualification/
requalification.
VII. REFERENCE
7.1. SOP-019435 Document Control Process
Monitoring Number of Microorganism in Cleanliness Class D
7.2. SOP-019574
HEPA & Cleanliness Class E
7.3. SOP-020104 Cleanliness Classes in PT. IHI
7.4. FM-012097 GxP Assessment Matrix
7.5. FM-021680 User Requirement Specification
7.6. FM-023883 Qualification Trial
7.7. FM-023884 Periodic Review
7.8. EFRM-0000623 Design Qualification Protocol
7.9. EFRM-0000622 Design Qualification report
7.10. FM-021681 Installation Qualification Protocol
7.11. FM-023885 Operational Qualification Protocol
7.12. FM-023886 Performance Qualification Protocol
7.13. FM-021682 Installation Qualification Report
7.14. FM-023887 Operational Qualification Report
7.15. FM-023888 Performance Qualification Report
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VIII. APPENDICES
8.1. Appendix 1: Flowchart of Qualification Activity.
8.2. Appendix 2: Sampling Size.
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e d
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e d
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A p
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untuk equipment
Audit 2018 Wicaksono
baru/ modifikasi
harus merujuk
kepada URS pada
saat melakukan
Design Qualification
Menyesuaikan tabel
fungsional penanggung
Point IV
jawab kualifikasi sesuai
WWSP 348
Impact Assessment dari
sebuah project disusun
Update Terkait
sebelum kegiatan Galih
Follow up AAP
4 instalasi dilakukan dan Mangun
JJRC Audit
dinamakan Design Wicaksono
2018
Point 6.6.5 Review. Hal ini
dimaksudkan memeriksa
kesalahan desain dengan
dampak langsung pada
kualitas produk sebelum
unit/ system berada pada
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Impacted Site(s)
IM-PT Integrated Healthcare_Jakarta_Indonesia,BL-PT Integrated
Healthcare_Jakarta_Indonesia.
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