d. christopher watts, ph.d. office of pharmaceutical science, cder, fda asq/fdc october 22, 2004...
TRANSCRIPT
D. Christopher Watts, Ph.D.D. Christopher Watts, Ph.D.Office of Pharmaceutical Science, CDER, FDAOffice of Pharmaceutical Science, CDER, FDA
ASQ/FDCASQ/FDCOctober 22, 2004October 22, 2004
Process Analytical TechnologyProcess Analytical Technology(PAT)(PAT)
The QuestionsThe Questions
• What is PAT?• Why is PAT necessary?• What does PAT mean to me?
– Industry– Regulator– Consumer
• How does PAT relate to other FDA Initiatives?
• Where are we going with PAT?
PAT PAT GuidanceGuidance
• Released September 29, 2004
• Scientific principles and tools supporting innovation– PAT Tools– Process Understanding – Risk-Based Approach– Integrated Approach
• Regulatory Strategy accommodating innovation – PAT Team approach to Review
and Inspection – Joint training and certification
of staff
What is What is PATPAT??
A system for:– designing, analyzing, and controlling
manufacturing– timely measurements (i.e., during processing)– critical quality and performance attributes – raw and in-process materials– processes
“Analytical“ includes:
– chemical, physical, microbiological, mathematical, and risk analysis
– conducted in an integrated manner
PATPAT = Process = Process UnderstandingUnderstanding
• A process is well understood when:
– all critical sources of variability are identified and explained
– variability is managed by the process
– product quality attributes can be accurately and reliably predicted
• Accurate and Reliable predictions reflect process understanding
• Process Understanding inversely proportional to risk
Why PAT? Why PAT? FDAFDA Perspective Perspective
An increasing burden on FDA resources:•~ 4,000 manufacturing supplements
annually•Unable to meet statutory biennial GMP
inspection requirement•Lower scrutiny of non-domestic
industry
Cost implications for the industry from:• Low manufacturing and QA efficiency
Dr. Janet Woodcock,FDA Science Board
Why PAT? Why PAT? Public HealthPublic Health PerspectivePerspective
US Drug products are of high quality, BUT:• Increasing trend toward manufacturing-related
problems• Recalls - 176 in 1998 rising to 354 in 2002• Loss of availability of essential drugs• Disruption of manufacturing operations• Negative impact on new drug approvals
• Efficient pharmaceutical development and manufacturing are vital components of the “Critical Path” leading to an effective U.S. health care system Dr. Janet Woodcock,FDA Science Board
Main points from this:
• High tech in R & D
• Relatively low tech in Manufacturing
• It matters
Big Pharma manufacturing costs are $ 90 Bn
Significantly more than R&D
Quality by Design: A Challenge to the Pharma Industry
(CAMP, R. Scherzer. FDA Sci. Board. 4/9/02)
The Genesis of The Genesis of PATPAT: A : A ProactiveProactive
InitiativeInitiative
• Began at ACPS Discussions in July, 2001• FDA Science Board Meetings (11/01, 4/02)
– Current state of Pharmaceutical Manufacturing• Industrial Practice• FDA Regulation
– Science Board support for FDA’s proposal to facilitate innovation
http://www.fda.gov/cder/OPS/PAT.htm#scienceboard
How can How can PATPAT help? help?Example: Current Tablet Example: Current Tablet
ProductionProduction
Raw Material
Dispensing
Blending Compression
Identification Tests (Chemical
Only)
Test Product Quality for
Release (Active Only)
No Tests (Time Based)
End-Product Focused Testing to Document
Quality
Process at Risk
Current Tablet Production: Current Tablet Production: Testing to Document QualityTesting to Document Quality
• What is the Product Test?– Typically 30 Tablets/batch (1,000,000)
• What process Information does this provide?– None. Testing is Product focused.
• Will we see “failures”?– Expect number of “failing” tablets/batch, even
though 30 tablets/batch “pass”– 4% of batches may fail, even though not
different from a “passing” batch
• Does this facilitate process understanding and control?– No
PATPAT Approach: Quality by Design Approach: Quality by DesignFocus on Process Understanding
• What parameters are critical to Product Quality?– Experimental Design
• How do we analyze these parameters?– K.I.S.
• How do we control these parameters throughout the process?– Feed-back/-forward
Experimental Design: Experimental Design: Establishing the “Establishing the “Critical Critical
Parameter(s)Parameter(s)””
*Critical to Product Quality
Parameter 1Disintegrant
Level*Parameter 3Parameter 4
Active Particle Size*
Interaction 1Interaction 2Interaction 3Interaction 4Interaction 5
PAT PAT Approach: Approach: Particle SizeParticle Size
Raw Material Dispensing
Understand Raw Material• Analyzer in Dispensing• What is the material?• What is Particle Size?• Predictive Models for Blend
PATPAT: : AnalyzeAnalyze and and ControlControl
Blending
• Analyzer on Blender• Particle Size?• Disintegrant mixed?
• Stop blend with desired particle size and mix (not time based)
Understand and Control Blend
Example: Current Tablet Example: Current Tablet ProductionProduction
Raw Material
Dispensing
Blending Compression
Identification Tests (Chemical
Only)
Test Product Quality for
Release (Active Only)
No Tests (Time Based)
End-Product Focused Testing to Document
Quality
Process at Risk
PATPAT Tablet Production Tablet Production
Compression
Functional Tests (Chemical and
Physical)
Validate Process Control
Control Blending (Particle Size &
Disintegrant Distribution)
Process Focused
Mitigate the Process Risk
Raw material Functionality &
Dispensing
Blending
Predictive Models
PATPAT:: Risk-Managed Risk-Managed Approach to Approach to Regulatory ScrutinyRegulatory Scrutiny
• Expect an inverse relationship between the level of process understanding and the risk of producing a poor quality product
• Well understood process less restrictive regulatory approaches to manage change
• Focus on process understanding can facilitate risk-managed regulatory decisions and innovation
Implementation OptionsImplementation Options• Under the facility's own quality system
– Inspections by the PAT Team or PAT certified Investigator can precede or follow PAT implementation.
• A supplement (PAS, CBE, etc) can be submitted prior to implementation– if necessary, an inspection can be performed by a PAT Team
or PAT certified Investigator before implementation.• A comparability protocol can be submitted
– Following approval of this comparability protocol by the Agency, one or a combination of the above regulatory pathways can be adopted for implementation
• To facilitate adoption or approval of a PAT process, manufacturers may request a preoperational review of a PAT manufacturing facility and process
The FDA PAT Team (ORA, CDER, CVM)The FDA PAT Team (ORA, CDER, CVM)
PAT Steering CommitteeDoug Ellsworth, ORA/FDADennis Bensley, CVM/FDA Patricia Lefler, ORA/FDAJoe Famulare, CDER/FDAKeith Webber, CDER/FDA
Frank Holcomb, CDER/FDAMoheb Nasr, CDER/FDA
Ajaz Hussain, Chair, CDER/FDA
PAT Review - Inspection Team
Investigators:Robert Coleman (ORA/ATL-DO)
Rebeca Rodriguez (SJN-DO)Erin McCaffery (NWJ-DO)
George Pyramides (PHI-DO)Dennis Guilfoyle (NELD)
Compliance Officers: Albinus D’Sa (CDER)Mike Gavini (CDER)
William Bargo (CVM)Brenda Uratani (CDER)
Reviewers:Norman Schmuff (CDER)Lorenzo Rocca (CDER) Vibhakar Shah (CDER)
Rosario D’Costa (CDER)Raafat Fahmy (CVM)Bryan Riley (CDER)
PAT Policy Development TeamAli Afnan, OPS/CDER
Chris Watts, OPS/CDERHuiquan Wu, OPS/CDER
PAT Training CoordinatorsJohn Simmons, Karen Bernard
and See Lam
The The FDA PAT TeamFDA PAT Team::Training & Training &
CertificationCertification• Summary
– Completed Initial Training Program– “Lessons Learned”– Continuing Education– Involve in Next Training– Guidance Finalization
• Team Approach– Review– Inspection– Peer Review
• FDA CGMP Initiative– Risk-based regulation– “Non-impeding” regulation– Consistent regulation
• Success based on Broad Cooperation– Industry– Academia– FDA
http://www.fda.gov/bbs/topics/NEWS/2002/NEW00829.html
PAT PAT and and CGMPCGMP Initiative Initiative
PATPAT and The and The “Critical Path”“Critical Path”
http://www.fda.gov/oc/initiatives/criticalpath/whitepaper.pdf
PATPAT and The and The “Critical Path”“Critical Path”
http://www.fda.gov/oc/initiatives/criticalpath/whitepaper.pdf
PAT, CGMP, and The Critical PAT, CGMP, and The Critical PathPath
Process Analytical
Technology
Encourage Innovation
New TechnologiesCGMP’s for
the 21st Century
The Critical Path
Risk-Management
Broad Cooperation:
Industry, Academia, FDA
International International CollaborationCollaboration
• ASTM Technical Committee E55
• International Regulators forming PAT Teams– Canada, Europe, Japan
• Invitation to Participate in Training
Guidance WorkshopsGuidance Workshops• Co-sponsored Public Workshops on PAT
Guidance– AAPS, ISPE, RPS
• US (Arlington, VA)– November 16, 2004
• Tokyo, Japan– December 8, 2004
• London, UK– December 14, 2004
• Brussels, Belgium– February 22, 2005
• Mumbai, India – February 25, 2005
SummarySummary• Finalized PAT Guidance
– Guidance Workshops• Expanded the Scope of PAT
– Office of Biotechnology Products• Continue Training of FDA Staff• Various Workshops (Global)
– AAPS, AIChE, IFPAC, ISPE• ASTM Technical Committee E55 on the
Pharmaceutical Application of PAT• Research (Intra- and Extramural)
– Pfizer CRADA– NSF IAG– Support Policy Development and Training
ContactContact
• Email:– [email protected]– [email protected]
• PAT on the Web:– http://www.fda.gov/cder/OPS/
PAT.htm• Phone:
– (301)-443-5197