Module 4 - Risk Assessment

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Module 4 – Risk Assessment

Heating, ventilation, and air system encompasses heating, ventilation, and air
conditioning, which is integral component of pharmaceutical facility
functionality.
The qualification of HVAC systems is done by using a risk based approach.
The risk management program consists of four major components:
1) Risk assessment,
2) Risk control,
3) Risk review, and
4) Risk communication.
All four components are essential. All the above methods should address the
mentioned four basic components.
Failure mode effect analysis (FMEA) concepts were used for risk assessment of a
HVAC system to determine the scope and extent of qualification and validation in
the work.
The HVAC is the “direct impact” system in the aseptic practice which directly
affects the product quality and regulatory compliance.
The level of risk associated with the HVAC system was assessed based on the
impact and severity of the probable risk in aseptic practice in sterile
manufacturing.
After completion of the risk assessment the recommended actions were extended
and verified against the qualification stages of the HVAC system.
The various parameters to be evaluated for the validation of HVAC system include
air flow pattern, air flow velocity, air changes per hour, filter leak test, particle
count, viable monitoring, filter integrity test, pressure difference, recovery test for
temperature and humidity, temperature and humidity uniformity, and fresh air
determination.
Validation of HVAC system involves systemized and assembled documents of
1) Functional specifications
2) Design drawings
3) Plans and specifications
4) Validation master plan
5) Testing, adjusting, and balancing (TAB) and
6) Startup reports.
Risk assessment (FMEA model)
Evaluate the overall risk of the qualification and validation steps by combining
individual risk values.
For the most of the direct impact system, the severity will always be high. The
risk priority ranking (RPR) then becomes a combination of an occurrence and
detection.
If the level of risk is not acceptable, a recommendation must be made to
modify the qualification and validation steps to reduce the risk to an
acceptable level or enhance the method of detection to reduce the risk to an
acceptable level.
Preference should be given to reducing the occurrence rather than increasing
the level of detection.
After completion of the risk assessment, the recommended action of
unacceptable risk extended to qualification stages of HVAC system to have a
high level of assurance and if the test result are not acceptable, carry out
corrective action that may include modification in the existing controls and the
system.
Qualification and validation is appearing to be the beginning of a continuous
development process in pharmaceutical QA.
Risk assessment is an essential tool for qualification of HVAC system in aseptic
processes.
It is not just a tool for cGMP compliance, its offers real benefits to the
validation process by identifying risks and ensuring that critical risks are
controlled.
By focusing on managing risks to the patient, pharmaceutical manufacturers
can ensure that the right resources are applied at the right place and at the
right time improving patient safety while eliminating unnecessary qualification
and validation efforts.

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