Sample URS For Isolator Following Flow Chart - User Requirements Specification
Sample URS For Isolator Following Flow Chart - User Requirements Specification
Sample URS For Isolator Following Flow Chart - User Requirements Specification
For
Contained High Hazard Systems
There are two approaches outlined in the charts within the document; one is a vendor design approach
and the other is containment specialist design approach.
Vendor Design
In this approach the user prepares the User Requirement Specification (URS)so that competing vendors
know what the user wants in terms of process capability outline for the Functional Requirements (FRS)
for the vendor to complete. A procurement document is prepared to instruct the bidder on the Technical
and Financial Requirements for the bid. The vendor then has to undertake a preliminary design and
provide documentation in the bid document that in the vendors judgment is sufficient to illustrate the
scope of supply and a corresponding price. This will vary greatly from vendor to vendor.
The stakeholder team then has to assess the bids comparing the various designs to select the best
(design, specification and cost) solution or to negotiate with one or more bidders to leverage changes
prior to award. A vendor is selected and the project awarded.
The vendor then undertakes design development, builds an ergonomic model and completes the FRS.
Any changes as a result of this process may result in a change order due to scope change. Once these
are approved, the vendor commences detail design and submits drawings and documentation for
approval by the stakeholders.
The process then moves through FAT, SAT, Functional, Surrogate, IQ and OQ protocols. The vendor
prepares the FAT, SAT and Functional protocols and submits them for stakeholder approval. The
stakeholders typically prepare IQ, OQ, PQ and Surrogate test protocols. Training on operation of the
isolator is by the vendor.
Specialist Design
In this route the stakeholders engage the services of an independent specialist to assist the stakeholders
in one or more of the tasks described below. In some cases the specialist can be provided design and
mock up review and this is shown before the bid process. This allows bids to be on a like for like basis.
The specialist designer can be anyone who in the opinion of the owner has the necessary experience and
credentials to perform the role. The specialist may be:
A company employee who specializes in containment and has sufficient in depth knowledge to
perform the role
An independent consultant with out attachment to any interested party. This consultant should be
able to fully design and evaluate the isolator system so that vendors do not need to perform
preliminary engineering and ergonomic review
Part of an A/E team. Be careful most if not all A/Es derive their information from vendors and
rarely if ever have hands on experience of isolators
A Vendor. Vendors have virtually no feedback from end users and the design is being developed
once an order has been placed so the two drivers are to look for variation orders and design to
achieve the profit margin. A vendor pre-design will alter other vendors and may result in high
pricing with minimal input.
If the specialist consultant option is chosen the normal course would be for the stakeholder team to
appoint the specialist at the outset. The specialist would then become part of the stakeholder team and
participate in the stakeholder activities, bring detailed specialist support to the URS and FRS process as
well as the design development and mock up assessment.
The consultant design approach
As soon as possible the stakeholder team appoints a specialist who assists the stakeholders in
developing the URS using the outline illustrated here. The consultant will also have experience which
enables the FRS to be written to benefit the user requirements uninfluenced by vendor preferences for
ease of construction, cost, etc.
As the URS is developed concept designs are reviewed and when appropriate a mock up is made at full
size for the stakeholder review. This involves the use of the actual tools and equipment to fully explore all
the interventions, process steps, etc. The operators are a vital part of this process. After the review is
complete the consultant develops detail design drawings (general arrangement) and schematics showing
how the isolator is to function as well as product flow routes. The specialist will customize the protocols
that have been developed by the consultant for FAT, SAT and Functional testing (IQ and OQ can be
included) so that the vendor prices for the supply of calibrated test equipment and personnel for the
witnessed protocols (FAT, SAT, Functional and Surrogate Test, etc).
The packages described above are bid out so that the comparison is on a like for like basis on a design
that has already been scrutinized by the stakeholders and which represents their requirements.
On award the vendor moves directly to fabrication drawings. The specialist provides witnessing/ support
for FAT, SAT and Functional testing. Start up support and debugging can also be provided and the
specialist provides full training for operation technique and administration of the isolator.
This route minimizes scope changes and maximizes the operability and performance of the system.
Table of Contents
The purpose of this template is to assist you in the preparation of the User Requirements Specification
URS) document for isolator systems. Please follow all applicable Pharmaceutical Sourcing Group
Americas (PSGA) standard operating procedures.
Paragraphs in blue italics font style are meant to serve as instructions to the author of this
document and to be deleted in the final version.
Paragraphs in black regular font style are sample wording that may be used as is or modified as
required. Should a sentence or paragraph not be needed, simply delete it from your document
This template contains all the sections required for an Isolator URS.
Major requirement section(s) in black regular font must be populated or, if not applicable,
must be retained in the document and labeled as such. Sub-sections in blue regular font
are optional and can be modified or deleted to accommodate your system.
Text in [BRACKETS] should be replaced with the appropriate information by the author.
Shaded numeric and/or text fields (field codes) in Gray (including the Table of Contents) must be
updated before publication of your document (right click on field and select Update Field).
User Requirements Specification (URS) are based on business and user needs and define what the user
wants the isolator system to do in clear and specific terms. Upon completion of this document a
Functional Requirements Specification (FRS) will be developed and provide standard specifications for
materials, finishes, HVAC and control systems including process interfaces that will satisfy the
requirements stated in this URS document. The requirements in this document specify the business and
functional requirements of your system. This includes the functional, security, data integrity, and
performance capabilities that must be provided in order to meet the business needs of the users of this
system in PSGA. The URS will also provide additional information to expand the project plan for realistic
tasks, dates and resources.
Requirements must be written in a complete and unambiguous manner that defines the system
functionality and/or component. Most importantly, the requirement should be testable. It should not
contain words or phrases such as, timely, quick, or user friendly, etc. Descriptions must include words
and phrases that command the presence of some feature, function or deliverable, such as: shall, will,
must, is required to, responsible for, or are applicable.
Requirements must be uniquely identified with a requirement number. The following is a standard format
that contains the requirement number, prefaced by the user requirement indicator of U and an
abbreviation of the requirement category.
Present the requirements in a table form with the requirement ID number, the description and the
requirement type refer to the example table below. A legend for the possible Type field entries
appears further below. The most commonly used types will be T for technical and P for procedural.
Depending on the type of requirements incorporated into your finished URS, consider adding a specific
legend with definitions that will facilitate reader understanding.
U-FR-01 The system shall allow the user to export raw data files from the ABC LIMS T
system in PDF format.
U-FR-02 A system specific SOP describing Backup & Restore procedures will be P
developed.
Operators must buy into the system and have to make it operate successfully they should
contribute to the development of the process.
Quality has to set acceptance criteria and ensure that the system complies with regulatory
requirements.
All stakeholders have to understand and appreciate the needs of others and understand that a
successful project stems from cooperation and collaboration. The project manager should
schedule and lead all stakeholder meetings and ensure that they are effective. The stakeholders
are responsible for developing the necessary data to allow the project to proceed in a timely cost
effective manner. In some cases the specialist consultant should be added to the stakeholder
team.
1.1 Introduction
[This section describes the isolator system by depicting its functionality, location and intended use
or purpose. The purpose of this document is for the users to clearly state what they intend to do in
the system and what features are necessary to perform the operations successfully. A user
requirement document will not specify materials and workmanship unless it has a direct process
impact. Most projects fail because there is no clear statement of the use of the system.]
The purpose of the User Requirements Specification (URS) is to define the business user needs
of the [System name and version number]. The User Requirements Specification will be the basis
of Qualification testing to ensure that user requirements are met.
The [Name] System is an isolator system that will be utilized by the [department/group and
location] to [purpose/intended use of the system]
1.2 Scope
[Describe the scope of the system being defined including site locations and major
components and / or interfaces to be included as a part of the system.]
1.3 Definitions
This section presents acronyms and definitions of terms specific to this document.
Term Definition
2.0 References
[This section should include all appropriate references for the project, including change approval
numbers, project management plan, validation plan, etc.]
[This section describes an overview of the manufacturing operations that will be covered by the
system. The description in this section sets the scope or boundaries of the functionality of the
system. Reference to operational procedures, product specifications and other documents impact
within the scope of the system may be identified in this section.]
When the compounds are unknown then a default should be used that is protective of the
occupational workforce. This default should be based on the worst characteristics that will be
expected.
Sensitizer
Mutagen
Carcinogen
Teratogen
Other phrases
Particle Shape*
Electrostatic Properties
Bulk Density*
Explosivity
Comments*
Particle Size
API/ Excipient Name
The comments column should indicate safe ranges such as oxygen >5%, heat 20 - 30C, etc.
Where the user has a required mitigation regimen it should be stated, so for oxygen the
required mitigation is inerting with nitrogen or the use of an amber light where there is not
prescribe mitigation it should be left to the functional specification or the vendor.
Others
Light
Heat
Oxygen
The data on the fire and explosion propagation characteristics should be clearly stated.
Where risk of explosion by solvent or powder concentration exists it should be clearly stated.
All powders and liquids (solvents) are to be listed and the vendor is to evaluate materials of
construction in accordance with these materials an those listed in 4.4.1.
This section describes the processes to which the API and excipients are subjected
Processes that occur before the API and excipients enter the system described in this URS.
This helps the designer understand how the system fits into the whole process. An example
would be:
The API is manufactured in China and is packed in liners in liners in fiber drums 12
diameter by 24 tall in random weights. On receipt the drum is opened in the warehouse
sample area and a sample is extracted for analysis. The drum is re-sealed and wiped down.
Representative samples may be received as part of the bulk fiber drum which will help to
minimize exposure but this may not be applicable to all sites. The team should verify
applicability with the local site.
ID Description Type
U-DP-1
U-DP-2
This section describes in detail the processes that are undertaken within the system
described in this document. A process flow diagram should be inserted showing the flow of
materials through the process(es) so that the reader can understand the detail that follows.
The process should be described in detail highlighting all interventions expected and
unexpected, for instance The Jet Mill suffers cold fusion every 5 10 minutes and has to be
solvent dissolved. Provision for a spare mill and solvent bath, cleaning is required. As
opposed to The material is mircronized.
Frequency: How often is the system likely to be used for the processes required?
Multiple times a day? How many times a day?
Daily?
Weekly?
Monthly?
Less frequently?
U-PR-1
U-PR-2
3.2.3 Pass-in
What passes into the system? What are the sizes and weights of the API(s)? Excipient(s)?
Equipment that passes in? Material that passes in? Do they pass in in a particular order?
Are there any special procedures required on pass in? For instance is a liner removed?
What is the container type? How many pass in, how often does this occur?
ID Description Type
U-PI-1
U-PI-2
What accuracies are required? What are the feed and discharge rates?
ID Description Type
U-PE-1
U-PE-2
ID Description Type
U-SB-1
U-SB-2
3.2.6 Labeling
At what stages is labeling required? What information is required and how will it be
generated? Will it be applied within the contained system? If so, how will the label get
there? State the parameters and not the solution unless a solution has already been
evaluated for instance sacrificial printer mounted in the isolator. Where are the labels
created? Where are they placed?
ID Description Type
U-LA-1
U-LA-2
3.2.7 Sampling
Clearly state all the points at which samples are taken, how they are taken, how much is
taken and from where it is taken. What happens to the sample once it is taken?
Failure to fully define sampling processes causes more isolator failures than any other factor.
Better to provide too much information than too little.
How long do results take? What happens to the sample materials while waiting for results?
Consider non-invasive real time verification (PAT) to perform tasks required.
ID Description Type
U-SA-1
U-SA-2
ID Description Type
U-PO-1
U-PO-2
U-UP-1
U-UP-2
[Suggestion: When writing User Requirements, try to begin with The user shall . . . with regards to
user needs. If a requirement needs to be written as The system shall . . . , chances are this is a
Functional Requirement because it identifies a system function. Such requirements should be
moved to the Functional Requirements Specification (FRS) document.]
NOTE: As stated above, user requirements need to focus on the user needs with the
exception of the Regulatory Section (21 CFR Part 11) that traces the regulation to system
functionality normally found in the FRS. However, since a GAMP category 1, 2, or 3
system does not require creation of an FRS, consider this document as a combined User &
Functional requirements Specification (UFRS) document. GAMP category 4 or 5 systems
may either combine requirement specifications in a similar fashion (UFRS), or if the user
and functional specifications are in separate documents, refer the FRS regulatory section
back to the URS regulatory section.
For each of the component requirement sections shown below please provide a high level
description for that section as it pertains to the busy process requirement the system will be
expected to meet or resolve. Complex systems may also include a process flow diagram. The
diagram may be placed in the respective section it is illustrating or placed as an appendix at the
end of this document. Specific descriptions for each sub category are given below.
Requirement sections appearing in black regular font must be populated or, if not
applicable, should be retained in the document and labeled as such (N/A). Requirement
sections or subsection appearing in blue regular font are optional and can be modified or
deleted to accommodate your system.
Summarized below are the suggested criteria for performing the air sampling to validate the effectiveness
of the engineering and work practice controls.
The criteria below will be used as part of a separate PO requisition for which IH air sampling will be
performed independently to validate the effectiveness of the vendors systems.
The objective of the sampling is to verify that the system / controls maintains operators exposures below
{insert OEL} g / m3 for {insert API} during normal routine operations at {insert site} handling JNJ
compounds for the following {insert controls}.
Analysis - The use of the validated analytical method for the active ingredient(s) being
assessed.
Type - Personnel breathing zone samples. For some processes and equipment area
samples may be appropriate in conjunction with the personal breathing zone samples.
Duration (sampling time) - For the duration of the task being performed under routine
situations.
Investigator - The sampling will be performed under the direction of a Certified Industrial
Hygienist or a by a Qualified IH.
Report - A draft report with the sampling results / conclusions needs to be prepared for
review by JNJ personnel before the report is finalized.
Activity description A brief description of the task, activities and the controls should be
provided.
4.2.1 Ergonomics
What is the occupational population characteristics, population type and size range?
Example: US Adults 5 95 percentile
If the occupational workforce includes any individuals with varying needs such as:
o Height outside the 5 95 percentile range
o Arm reach outside the 5 95 percentile range
o Frontal features (maximum weight and reach permitted) that limit arm insertion
into gloves
o Other factors affecting ergonomic performance
These should be stated in a respectful manner. A copy of any EH&S guides on weight,
reach, lift should be attached. A clause requiring an ergonomic model is required to allow
review by the stakeholders.
The vendor/ specialist (delete what does not apply) will be responsible for the construction of
a mock-up at full size and providing where possible the transfer system. The owner will
provide typical equipment to allow a full evaluation of all the operations listed in 3.2.2. The
ergonomic evaluation is to be at a location agreed by the owner.
ID Description Type
U-ER-1
U-ER-2
4.2.2 Safety
Occupational Exposure to:
o Moving parts
o Heat
o Cold
o Corrosives
o Radiation
o Etc
Describe and limited if the risk is not present in the processes there is no need to state the
limits.
ID Description Type
U-SF-1
U-SF-2
4.2.3 Guarding
User preferences for mitigations should be stated.
o E-stops (not the isolator)
o Guards
o Light fences
o Barriers, etc
ID Description Type
U-GA-1
U-GA-2
ID Description Type
U-PCC-1
U-PCC-2
ID Description Type
U-PDC-1
U-PDC-2
4.3.3 Process Equipment Interface with the System
The user is to state what processes should be controlled from a combined man machine
interface, if any. Certain parameters are essential to communicate to the system controller;
for instance over pressure caused by the process equipment must be addressed by the
containment system or the source shut down to prevent a failure of the containment
boundary (glove and glazing failure).
U-CLN-1
U-CLN-2
ID Description Type
U-CMA-1
U-CMA-2
ID Description Type
U-MAC-1
U-MAC-2
4.4.3 WIP
User feature required for a repeatable cycle for wet in place or wash in place. Features to
consider: (select appropriate equipment)
o Spray nozzles
o Spray wands
o Manifold
o Drains
o WIP skid
ID Description Type
U-WIP-1
U-WIP-2
ID Description Type
U-CIP-1
U-CIP-2
ID Description Type
For negative pressure applications a feature that allows the blower to ramp to full capacity
when a breach occurs can be incorporated, is often referred to as Glove Inrush. Typically
velocities in the 60 -90 fpm range are required to minimize exposure to the operator.
ID Description Type
U-ICS-1
ID Description Type
U-ICS-2
ID Description Type
U-BR-1
U-BR-2
ID Description Type
U-DR-1
U-DR-2
ID Description Type
U-IR-1
U-IR-2
ID Description Type
U-CS-1
U-CS-2
F-PR-1
F-PR-2
Items to consider:
o Exhaust of air stream from isolator
o User material air lock (MAL) requirements and features
o User personnel air lock (PAL) pass in and pass out
o User access to equipment
ID Description Type
F-EnR-1
F-EnR-2
5.0 Regulatory Requirements
Include regulatory requirements. Include security, data integrity, validation, predicate rules and 21
CFR Part 11 requirements. Include requirements for user roles and levels of access, network
security, and system access control, logical and physical access. Data Integrity and Part 11
requirements include interface security, error handling, audit trails, data migration and change
control. In addition, both technical and procedural control requirements for Part 11 validation shall
be included. The sample requirements provided below cover all aspects of the Part 11 regulation.
Some of the requirements may not be applicable to this system, such as, electronic signatures. For
all other part 11 requirements that cannot be met from a technological standpoint by the systems
capabilities, a procedural solution will be required. Requirements in black regular font should be
considered boiler plate and must appear in your requirements document. Requirements in blue
italics can be considered optional depending on your system.
.
5.1.1.1 Passwords
ID Description Type
The system must log a user off after a defined period of inactivity.
U-ID-8
5.1.1.3 Logical Security Other
ID Description Type
The system shall be placed behind the corporate firewall or
U-SO-1
incorporate firewall software or other methods for protection from
the internet.
Before production, the System Owner will ensure that a Security
U-SO-2
SOP is developed and made effective. The SOP will include
physical and logical security (as applicable: application security,
network security, access authorization, creating new accounts,
modifying accounts, deleting/disabling accounts, periodic
checking of access and approval by the System Owner or
designee).
The system shall utilize anti-virus software that is updated
U-SO-3
regularly to prevent viruses corrupting data.
The system shall have the capability to only accept input data or
U-SO-4
instructions from specified input devices.
5.1.2.1 Physical
ID Description Type
The Server room must be secured.
U-PS-1
Access to the computer room must be restricted to authorized
U-PS-2
personnel and controlled by card access.
The workstation must have an anti-theft device.
U-PS-3
ID Description Type
The system shall be able to detect invalid records that contain
U-ER-1
invalid field entries.
The system shall be able to detect invalid records that contain
U-ER-2
blank fields that should contain data.
The system shall be able to detect invalid records that contain
U-ER-3
out-of-bound values.
The system shall display the entire contents of the electronic
U-ER-4
ID Description Type
record.
The system shall have the ability to print the entire contents of the
U-ER-5
electronic record.
The system shall retain the meaning and content of electronic,
U-ER-6
printed, or copied records.
The system shall have the capability to extract electronic records
U-ER-7
in an electronic format that can be read by a regulatory agency.
The system shall have the capability to exclude confidential
U-ER-8
annotations attached to an electronic record before supplying an
electronic copy to the regulatory agency.
The system will not allow steps to be bypassed.
U-ER-9
If applicable, the system will enforce a sequence of steps or
U-ER-10
events.
If applicable, the system will only allow data input from specified
U-ER-11
terminals or instruments at specified locations.
ID Description Type
The system must have a secure, computer generated, time
U-AT-1
stamped, audit trail that independently records the date and time
of operator entries, actions that create, modify, and delete
electronic records and the reason for the change.
The system must have an audit trail that is protected from
U-AT-2
intentional or accidental modifications.
The system will be able to record a change to an electronic
U-AT-3
record, and the previously recorded information is not obscured
by the change.
The electronic records audit trail is retrievable throughout the
U-AT-4
records retention period.
The system must be able to produce the audit trail in read only
U-AT-5
electronic format and can be printed in human readable format.
Any one individual user or administrator, must not have the
U-AT-6
capability to disable the systems audit trail.
The systems audit trail must be impossible to disable without
U-AT-7
detection.
Before going into production the system must have clearly
U-AT-8
defined retention periods for electronic and meta data.
The systems audit trail will capture e-signatures and associated
U-AT-9
time, date and meaning of change.
5.4 Handwritten Signature Requirements
If this is a hybrid system, include any requirements in addition to those stated below in the
table.
ID Description Type
The system shall link handwritten signatures to their electronic
U-HS-1
record counterpart via a unique version numbering schema.
Prior to production deployment, procedures will indicate how the
U-HS-2
paper copy is assured to be a complete and accurate copy of the
electronic record, the process for signing and maintaining the
paper copy, and the method for protecting the electronic record
from any future modification.
The system shall prompt for re-signatures for new versions of the
U-HS-3
changed electronic record.
The system shall not obscure any information in a signed or
U-HS-4
previously signed version of an electronic record.
ID Description Type
The electronic signature component for each user of the system
U-ES-15
will be made up of the unique user identification code and
password.
Single continuous e-signature session signings will utilize both
U-ES-16
components of the users e-signature for the initial session and
the users private password component for subsequent signings
[please define the period of continuous use here or as a separate
requirement in this section].
ID Description Type
The system shall not allow an electronic signatures combination
U-ES-17
of a user ID and password components to be duplicated for use
by another individual.
The systems password file must be encrypted so that passwords
U-ES-18
cannot be viewed by ordinary means.
ID Description Type
Prior to production, procedures will be implemented directing
U-ES-19
action to be taken to electronically deactivate lost, stolen,
missing, or otherwise potentially compromised tokens, cards, and
other devices used to carry or generate electronic signature
components.
Prior to production, procedures will be implemented for managing
U-ES-20
and controlling temporary or permanent token / card
replacements.
Prior to production, procedures will be implemented covering the
U-ES-21
initial and periodic testing of devices, such as tokens or cards,
that bear or generate identification code or password information.
Prior to production, procedures will be implemented to conduct
U-ES-22
testing on devices to include checks for proper functioning,
performance degradation, and detection of unauthorized
alterations.
ID Description Type
The system shall be designed to ensure that electronic signatures
U-ES-23
based on biometrics can only be used by their genuine owners.
5.6 Backup, Recovery, Archive, Restore Requirements
Include all backup, recovery, archive, and restore requirements, such as, data recovery,
redundancy, and recovery from system failures.
ID Description Type
Prior to production, an SOP shall be developed to establish
U-BR-1
procedures for Backup, Recovery, Archive and Restore.
The system shall be backed up on a regular basis, including full
U-BR-2
system backup, incremental backup, weekly, and monthly of all
electronic records including meta data (audit trail records).
A copy of all system backups shall be stored off site.
U-BR-3
The system shall have the capability to archive electronic data,
U-BR-4
including meta data (audit trails).
The system shall have the capability to restore electronic data,
U-BR-5
including meta data (audit trail) within a 24-hour period.
Prior to production, a system contingency plan will be in place.
U-BR-6
The contingency plan shall be reviewed on a regular basis.
U-BR-7
The contingency plan will be tested.
U-BR-8
ID Description Type
The training department shall maintain records for system training
U-TR-1
of all business areas involved in systems development,
maintenance, administration, or use.
Documentation will be maintained to show that persons
U-TR-2
(employees, temporary and contractors) who develop the system
have the education, training, and experience to perform their
assigned tasks.
Documentation will be maintained to show that persons
U-TR-3
(employees, temporary and contractors) who maintain the system
have the education, training, and experience to perform their
assigned tasks.
Documentation will be maintained to show that persons
U-TR-4
(employees, temporary and contractors) who use the system
have the education, training, and experience to perform their
assigned tasks.
Training manuals will be developed.
U-TR-5
5.8 Documentation Requirements
Include the system specific documentation requirements here.
ID Description Type
The distribution of, access to, and use of the systems operation
U-DR-1
and maintenance documentation will be controlled.
The systems old documentation will be retrieved or withdrawn
U-DR-2
when new versions are issued.
One copy of each of the systems superceded documentation will
U-DR-3
be maintained for future reference.
Access to all system documentation deemed sensitive in nature
U-DR-4
will be restricted to authorized persons in accordance with their
job duties.
System documentation will be under formal revision and change
U-DR-5
control procedures to maintain an audit trail that documents time-
sequenced development and modification of systems
documentation.
All systems documentation will contain revision history and be
U-DR-6
version controlled.
System documentation will be maintained in One Source, which
U-DR-7
maintains an audit trail of changes.
ID Description Type
U-OR-1
U-OR-2
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History of Change