SOP Guide for Pharma

Aerosol: SOP for Change Control in Equipment Validation – V 2.0

Aerosol: SOP for Change Control in Equipment Validation – V 2.0

SOP for Change Control in Equipment Validation

Department Aerosol
SOP No. SOP/Aerosol/140/2025
Supersedes SOP/Aerosol/140/2022
Page No. Page 1 of Y
Issue Date 06/02/2025
Effective Date 16/02/2025
Review Date 06/02/2028

1. Purpose

The purpose of this Standard Operating Procedure (SOP) is to provide guidelines for managing changes to equipment during the validation process in aerosol manufacturing. The SOP ensures that any changes made to the equipment, its components, or its operation are evaluated and documented, with appropriate testing and revalidation conducted to verify that the equipment continues to meet the required specifications and perform as intended.

2. Scope

This SOP applies to all aerosol manufacturing equipment undergoing validation, including equipment used in the filling, crimping, mixing, and packaging stages. It covers the change control process during the equipment validation lifecycle, including the evaluation, documentation, approval, and testing of changes that may affect equipment performance, compliance, or quality.

3. Responsibilities

  • Engineering Team: Responsible for identifying, assessing, and implementing changes to equipment. The team ensures that any changes made are properly documented, and that validation is performed if required.
  • Maintenance Team: Responsible for identifying any maintenance needs or changes required for the equipment and communicating those needs to the Engineering team for evaluation.
  • Production Team: Responsible for identifying and reporting any operational issues that may
require changes to the equipment or process, and ensuring that the equipment operates according to specifications after changes are made.
  • Quality Assurance (QA) Team: Responsible for reviewing and approving all changes and ensuring that the equipment revalidation process is followed to maintain compliance with GMP standards and regulatory requirements.
  • Change Control Board (CCB): Responsible for evaluating and approving changes that affect equipment performance, ensuring that the changes do not compromise product quality or compliance.
  • 4. Accountability

    The Manufacturing Manager is accountable for ensuring that any changes to equipment during validation are managed according to this SOP. The overall compliance with this SOP is overseen by the Quality Assurance (QA) Manager.

    5. Procedure

    5.1. Identifying Changes

    1. Any changes to equipment, its components, or its operation should be identified by the Engineering, Maintenance, or Production teams. These changes may include, but are not limited to:
      • Modification or replacement of equipment parts
      • Changes in machine settings or operating parameters
      • Installation of new software or control systems
      • Upgrades to equipment to meet regulatory requirements or improve performance
    2. All changes should be documented in the Change Control Log (Annexure-1) and submitted for evaluation.

    5.2. Evaluating Changes

    1. Upon identification of a change, the Change Control Board (CCB) should be convened to evaluate the impact of the change on equipment performance and product quality. The CCB will consider the following:
      • Whether the change will affect equipment performance, operational parameters, or quality control
      • Whether the change impacts previously conducted validation activities (e.g., Installation Qualification (IQ), Operational Qualification (OQ), Performance Qualification (PQ))
      • Whether revalidation or additional testing is required
      • The regulatory and compliance implications of the change
    2. Document the evaluation results, including the reason for the change and any required actions (e.g., revalidation, retesting, adjustments).

    5.3. Implementing Changes

    1. Once a change is approved by the CCB, the necessary modifications should be made to the equipment or process as per the approved change plan.
    2. The Engineering and Maintenance teams are responsible for implementing the changes according to the approved specifications. During implementation, all activities should be documented to ensure traceability and accountability.
    3. If revalidation or additional testing is required, it should be planned and executed as outlined in the original validation protocol or any updated testing protocols.

    5.4. Documenting the Change Control Process

    1. All changes must be documented in the Change Control Log (Annexure-1) and should include the following details:
      • Change ID
      • Description of the change
      • Reason for the change
      • Impact on equipment performance, compliance, or product quality
      • Testing or validation required post-change
      • Implementation details
      • Approvals from the Change Control Board and other relevant stakeholders
    2. Ensure that the documentation is clear, complete, and accessible for future reference or audits.

    5.5. Revalidating the Equipment After Changes

    1. If the change affects the equipment’s performance, compliance, or product quality, revalidation will be required. This may include:
      • Reinstalling equipment and performing Installation Qualification (IQ)
      • Conducting Operational Qualification (OQ) to ensure the equipment operates as expected
      • Completing Performance Qualification (PQ) to verify the equipment produces the desired product quality
    2. Ensure that all validation tests are documented in the Equipment Revalidation Report (Annexure-2), and any deviations or corrective actions are recorded in the Deviation Log (Annexure-3).
    3. The QA team should review and approve the revalidation results, ensuring that all tests are successful and the equipment is compliant with regulatory requirements.

    5.6. Closing the Change Control Process

    1. Once all changes have been implemented and any required revalidation is complete, the Change Control process can be closed.
    2. The Change Control Log should be updated to reflect that the change has been completed and all necessary testing, documentation, and approvals are in place.
    3. Ensure that the final documentation is archived for future audits and inspections.

    6. Abbreviations

    • GMP: Good Manufacturing Practice
    • QA: Quality Assurance
    • SOP: Standard Operating Procedure
    • CAPA: Corrective and Preventive Action
    • OQ: Operational Qualification
    • PQ: Performance Qualification
    • IQ: Installation Qualification

    7. Documents

    1. Change Control Log (Annexure-1)
    2. Equipment Revalidation Report (Annexure-2)
    3. Deviation Log (Annexure-3)

    8. References

    This SOP is based on the following regulatory guidelines and industry standards:

    • Good Manufacturing Practice (GMP) Guidelines
    • FDA Code of Federal Regulations (CFR) Title 21, Part 211
    • International Council for Harmonisation (ICH) Guidelines

    9. SOP Version

    Version: 2.0

    10. Approval Section

    Prepared By Checked By Approved By
    Signature
    Date
    Name
    Designation
    Department

    11. Annexures

    Annexure-1: Change Control Log

    Change ID Change Description Reason for Change Impact Approval Status Implementation Date
    CC-001 Installed new sensor in filling machine Improved measurement accuracy No impact on performance Approved 06/02/2025

    Annexure-2: Equipment Revalidation Report

    Equipment ID Model Number Serial Number Test Date Test Type Result
    FILL-001 Model A SN123456 06/02/2025 Revalidation Test Pass

    Annexure-3: Deviation Log

    Deviation ID Deviation Description Corrective Action Assigned To Status
    DEV-12345 Sensor malfunctioned Replaced sensor Rajesh Patel Completed

    12. Revision History:

    Revision Date Revision No. Revision Details Reason for Revision Approved By Page No. Ref. Point No. Details of Revision
    01/01/2024 V 1.0 Initial Release First Issue Anjali Sharma Page 1 [Ref Point] First Release
    01/01/2025 V 2.0 Updated change control procedures To comply with updated GMP regulations Anjali Sharma Page 1 [Ref Point] Updated procedures
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