Standard Operating Procedure for Replacement of Worn-out Parts

1) Purpose

The purpose of this SOP is to establish the procedures for the timely and proper replacement of worn-out parts in pharmaceutical manufacturing equipment to ensure continuous operation and product quality.

2) Scope

This SOP applies to all pharmaceutical manufacturing equipment requiring replacement of worn-out parts, including production machinery, laboratory instruments, and utilities.

3) Responsibilities

The Facility Management Department is responsible for implementing and adhering to this SOP. The Maintenance Team is responsible for executing replacement activities.

4) Procedure

1. Identification of Worn-out Parts
   1. Regularly inspect equipment for signs of wear, including visual inspection, performance degradation, and abnormal noise or vibrations.
   2. Use manufacturer guidelines and maintenance history to identify parts approaching the end of their service life.
2. Replacement Planning
   1. Develop a replacement plan based on equipment criticality, manufacturer recommendations, and operational history.
   2. Order replacement parts from approved suppliers.
   3. Schedule replacement activities to minimize equipment downtime.
3. Replacement Procedure
   1. Shut down equipment following lockout/tagout procedures.
   2. Remove worn-out parts using appropriate tools and techniques.
   3. Inspect replacement parts for quality and compatibility.
   4. Install new parts following manufacturer specifications and using approved procedures.
4. Post-Replacement Verification
   1. Test equipment functionality to ensure proper installation of replacement parts.
   2. Monitor equipment performance post-replacement.
   3. Address any issues or adjustments needed.
5. Record Keeping
   1. Maintain detailed records of all replacement activities.
   2. Document replacement plans, parts