Standard Operating Procedure for Operator Training on Solvent Safety in API Manufacturing
| Department | API Manufacturing |
|---|---|
| SOP No. | SOP/API/055/2025 |
| Supersedes | SOP/API/055/2022 |
| Page No. | Page 1 of 10 |
| Issue Date | 13/04/2025 |
| Effective Date | 15/04/2025 |
| Review Date | 13/04/2026 |
1. Purpose
To provide a standardized framework for the training of API manufacturing operators on the safe handling, storage, and disposal of solvents to ensure personnel safety, process efficiency, and regulatory compliance.
2. Scope
This SOP applies to all production and maintenance personnel involved in the handling, storage, recovery, and disposal of solvents in API manufacturing.
3. Responsibilities
- Training Coordinator: Develop and update solvent safety training modules.
- EHS Officer: Deliver training and assess risk awareness.
- Departmental Supervisor: Nominate participants and track attendance.
- QA Department: Review training effectiveness and maintain records.
4. Accountability
The Head of Manufacturing is accountable for ensuring all relevant operators receive solvent safety training. The EHS Manager is responsible for the training content and delivery.
5. Procedure
5.1 Training Schedule and Nomination
- Conduct solvent safety training:
- During onboarding of new operators
- Annually for existing personnel
- After major solvent-related incidents or process changes
- Supervisors shall submit nominations via the “Training Nomination Form” (Annexure-1).
5.2 Training Content
- Topics to be covered:
- Classification of solvents (flammable, toxic, reactive)
- Labeling and storage guidelines
- Use of PPE and safe handling procedures
- Emergency response to spills and fire
- First-aid measures for solvent exposure
- MSDS interpretation
- Waste segregation and disposal
- Use a combination of classroom training, videos, demonstrations, and practical assessments.
5.3 Evaluation and Certification
- Conduct a written and/or practical assessment post-training.
- Minimum passing score: 75%
- Issue “Solvent Safety Training Certificate” valid for one year (Annexure-2).
5.4 Record Keeping and Monitoring
- Maintain a “Training Attendance and Assessment Record” (Annexure-3).
- QA to verify training records during GMP audits and internal reviews.
- Refresher training shall be scheduled if:
- New solvent type is introduced
- A fire/spill incident occurs
- Regulatory guidelines are updated
6. Abbreviations
- SOP: Standard Operating Procedure
- PPE: Personal Protective Equipment
- EHS: Environment, Health and Safety
- MSDS: Material Safety Data Sheet
- QA: Quality Assurance
7. Documents
- Training Nomination Form (Annexure-1)
- Solvent Safety Training Certificate (Annexure-2)
- Training Attendance and Assessment Record (Annexure-3)
8. References
- ICH Q9 – Quality Risk Management
- OSHA Standard 1910.1200 – Hazard Communication
- GMP Training Guidelines for Pharmaceutical Industry
9. SOP Version
Version: 2.0
10. Approval Section
| Prepared By | Checked By | Approved By | |
|---|---|---|---|
| Signature | |||
| Date | |||
| Name | |||
| Designation | |||
| Department |
11. Annexures
Annexure-1: Training Nomination Form
| Employee Name | Department | Designation | Training Date | Nominated By |
|---|---|---|---|---|
| Ravi Singh | Production | Operator | 15/04/2025 | Shift In-Charge |
Annexure-2: Solvent Safety Training Certificate
This is to certify that [Employee Name] has successfully completed solvent safety training on [Date] and is authorized to handle solvents in the API manufacturing unit.
Annexure-3: Training Attendance and Assessment Record
| Name | Department | Score (%) | Status | Trainer |
|---|---|---|---|---|
| Ravi Singh | Production | 85 | Passed | EHS Officer |
Revision History:
| Revision Date | Revision No. | Details | Reason | Approved By |
|---|---|---|---|---|
| 01/01/2022 | 1.0 | Initial Release | Training System Implementation | QA Head |
| 13/04/2025 | 2.0 | Assessment Criteria and Certificate Format Added | Audit Observation | QA Head |