Author : Kirstie Hunt
Publisher :
ISBN 13 :
Total Pages : pages
Book Rating : 4.:/5 (99 download)
Book Synopsis Implementing a Curriculum for Improving Accuracy of Real-time Comments in Electronic Batch Records for Genentech, Inc by : Kirstie Hunt
Download or read book Implementing a Curriculum for Improving Accuracy of Real-time Comments in Electronic Batch Records for Genentech, Inc written by Kirstie Hunt and published by . This book was released on 2017 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: Genentech is a biopharmaceutical company located in Oceanside, CA. The Oceanside campus is one of five locations within the United States and is a multi-product drug substance Manufacturing facility of biopharmaceuticals. The Manufacturing production plant is controlled by an automated system called DeltaV, which facilitates the processing equipment to effectively produce biopharmaceuticals. DeltaV has the ability to track any process recordable including: alarms, holds/restart, overrides, and process interventions; simultaneously recording them to an Electronic Batch Record (EBR). In addition to the automated control system, Manufacturing bioprocess technicians provide manual support and oversight for the process operations and equipment. There are a multitude of Standard Operating Procedures (SOP), work instructions, training modules, instructor-led courses and other tools that provide guidelines and information for employees to perform compliant operations. EBRs are official Good Manufacturing Practice (GMP) documents that provide an audit trail for all manufacturing processes. The EBR is segmented into different sections including: material usage, equipment usage, batch formula, procedure details, phase details, failure messages, alarms, and process interventions. The EBR is generated real-time while a process recipe is running in DeltaV and populates the information to the Manufacturing Execution System (MES) or Syncade. Completed EBRs are compiled into the MES queue and undergo Manufacturing Quality Assurance (MQA) review, Manufacturing review, MQA approval and then become archived once the process is complete. Each step within the review process is tedious and time consuming, requiring acquisition of relevant information and a high degree of patience and technical accuracy to ensure the job is done correctly. It is the responsibility of MQA to make note of any issues, inconsistencies, or missing components within the completed record. It is the responsibility of the Manufacturing Department to address MQA's instructions with an appropriate comment. This review process is prolonged if comments are not entered real-time, thus generating more time in the review process and extensive investigation. There are a number of EBRs that require rework, which adds complexity, time, and non-value to the operations, thus costing Genentech money by impacting lot disposition and ultimately patients receipt of medication in a timely manner. Genentech would like to codify a solution for technicians to compose right the first time comments that are written real-time and reduce the percentage of batch records that are not completed correctly. This project aims to successfully analyze and implement a resourceful solution to the issue at hand. The DMAIC approach was conducted in order to identify and analyze the contributing elements that pose a threat to right the first time batch records. The DMAIC model is comprised of the following components: Define, Measure, Analyze, Improve and Control. The DMAIC approach is highlighted as a core component to the Six Sigma methodology, which is widely used as an industry standard. Six Sigma is a disciplined methodology for eliminating defects in Genentech's manufacturing process. The utilization of this concept has allowed for a development and implementation of an instructor-led training curriculum titled Right the First Time Comments Training. The idea of incorporating an instructor-led training course stemmed from studies stating it was a more effective and engaging method of encoding the content to trainees. Reportedly, 70% of learning comes from on the job practice (Heathfield, 2016), thus guiding the instructor-led training course to incorporate a variety of real life simulations that engage the attention of the trainees. The objective of the training course is to teach technicians how to write batch comments that are right the first time in order to avoid mistakes that may cause unnecessary re-work and delays. Upon completion of this course technicians will be equipped to navigate through MES/Syncade and DeltaV, locate in-process batch records, utilize process historian, identify SOP linkages, and properly write a comment.