- Date:
-
- Webinar
GMP-gerechte Wartung/Instandhaltung & Kalibirierung (PT 3 & PT 4) - Live Online Seminar
- Event location:
- online
- Organizer:
- CONCEPT HEIDELBERG GmbH
GMP-compliant Maintenance/Repair (PT 3)
Topic Block 1: Fundamentals
The importance of maintenance is increasing both economically and as a sub-aspect of GMP-compliant manufacturing. Guidance is provided for technically responsible personnel, based on regulatory frameworks. The implementation of these frameworks into a "liveable" practice will be presented during the lecture.
The importance of maintenance is increasing both economically and as a sub-aspect of GMP-compliant manufacturing. Guidance is provided for technically responsible personnel, based on regulatory frameworks. The implementation of these frameworks into a "liveable" practice will be presented during the lecture.
- The regulatory frameworks
- Quality system Maintenance throughout the lifecycle of a facility
- GMP requirements in maintenance
- Increasing plant availability, challenges for the maintenance technician
- Reproducibility of maintenance activities
Topic Block 2: Approach to Maintenance
From the start of a project, future maintenance measures must be planned (e.g., accessibility of a facility). During the project, aspects such as maintenance intervals and spare parts inventory must be discussed and decided. This also has significant cost implications. For a finished, operational facility, maintenance measures should follow established rules.
From the start of a project, future maintenance measures must be planned (e.g., accessibility of a facility). During the project, aspects such as maintenance intervals and spare parts inventory must be discussed and decided. This also has significant cost implications. For a finished, operational facility, maintenance measures should follow established rules.
Maintenance in Planning
- Maintenance planning during qualification phase
- Warranty
- Standardization
- Constructive possibilities
- Determination of intervals and contents
- Internal and external activities
- Maintenance contracts
- Spare parts planning
- Risk analysis, supplyability, consignment stock
- Management
From Project to Maintenance – Establishing a System for Organizing GMP-compliant Maintenance
- Overview of the maintenance project
- Creating and maintaining I&W plans
- Carrying out maintenance measures with the required documentation
- Establishing and maintaining GMP-compliant plant documentation
- Calibration as a special case of maintenance work
Risk-Based Maintenance
- Qualifications: internal vs external maintenance
- Are maintenance contents from the equipment supplier sufficient?
- Determining maintenance contents through risk analyses
- Using experience data
- Determining suitable materials and auxiliaries in maintenance execution
- Evaluation of GMP documentation to determine maintenance contents
- Deviations, complaints
- Logbooks
- Maintenance documentation
Hygiene in Maintenance
- Critical weak points in pharmaceutical equipment
- Typical weaknesses in maintenance
- How to avoid unhygienic situations?
- How to recognize hygiene problems
- Hygienic contamination sources in maintenance
- The craftsman
- The tools / aids
Topic Block 3: Practical Examples
GMP-compliant maintenance requires systems that maintain documented qualified equipment status throughout the entire usage period. This can be achieved in various ways. The lectures present a practiced maintenance process through which all maintenance activities are evaluated, categorized, and documented under GMP considerations.
GMP-compliant maintenance requires systems that maintain documented qualified equipment status throughout the entire usage period. This can be achieved in various ways. The lectures present a practiced maintenance process through which all maintenance activities are evaluated, categorized, and documented under GMP considerations.
Practical Example: Maintenance of a Water System
- Components subject to maintenance
- Hygiene requirements
- Spare parts
- Intervals
- Cleaning and disinfection
- Qualification of internal and external resources
- Documentation
Examples: Maintenance of Production Equipment and HVAC Systems
- Practical examples
- Classification of criticality
- Special requirements and tips & tricks
- Examples of deriving maintenance activities
- A walk through non-sterile and sterile manufacturing
- Special features in maintaining HVAC systems
Topic Block 4: IT Support
The specific requirements in the pharmaceutical environment and the resulting challenges regarding data collection, structuring, documentation, and integrity can be addressed and managed with IT solutions. The information generated from an IT-supported maintenance process can be used for plant optimization as well as for troubleshooting documentation. Particularly, integration with other GMP interfaces such as change control and deviation management is of governmental interest.
The specific requirements in the pharmaceutical environment and the resulting challenges regarding data collection, structuring, documentation, and integrity can be addressed and managed with IT solutions. The information generated from an IT-supported maintenance process can be used for plant optimization as well as for troubleshooting documentation. Particularly, integration with other GMP interfaces such as change control and deviation management is of governmental interest.
Practical Example CSL Behring: IT-based Maintenance in SAP and Paperless Documentation
- Criteria for IT use in maintenance
- Explanation of organization, master data management, and process flow in SAP
- Transition to paperless maintenance
- Explanation of maintenance process using mobile devices
- Practical example: Troubleshooting
Maintenance 4.0 in the Pharmaceutical Industry
- Cybersecurity challenges
- Digital documentation from GMP and legal perspectives
- Data integrity & MES & digital signatures
- New approaches through 3D printing and scanning technology
- Production gains through a like-for-like approach
- Extended capabilities for Condition Maintenance
GMP-compliant Calibration (PT 4)
Calibration from a GMP Inspector's Perspective
- GMP regulations, calibration laws, standards, and guidelines
- Traceability of calibration
- Calibration management, intervals, deviations from GMP perspective
- Calibration protocols – evaluation, practical examples, and common errors
Test Equipment, Test Equipment Management, and Documentation
- Examples of developed software for test equipment management
- Recalibration of test equipment
- Certification of test equipment / DKD certificates / factory tests
- Calibration protocols (structure and content)
- Management of measurement data
Technical Fundamentals of Calibration of Sensors, Transmitters, and Display Devices
- Calibration of the complete measurement chain
- Calibration of individual elements of the measurement chain (sensors, transmitters, display devices)
Plant Calibration in Connection with Qualification
- Qualification documentation
- Inclusion of calibration documents
- Re-qualification / recalibration
- Practical examples
- Temperature measurement
- Pressure measurement
Measurement Uncertainty
- Systematic and unsystematic measurement errors
- Estimation / calculation and example measurement
- Uncertainty budget

CONCEPT HEIDELBERG GmbH
Rischerstraße 8
69123 Heidelberg
Germany
Phone: +49 6221 844415
Fax: +49 6221 844464
email: info@concept-heidelberg.de
Internet: http://www.gmp-navigator.com/








