Co., Ltd. Plant Site Master File
Co., Ltd. Plant Site Master File
Co., Ltd. Plant Site Master File
□□ Plant
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Table of Contents
1.2 Authorized pharmaceutical manufacturing activities of the site including those from foreign regulatory
authorities
3 Personnel
4.1 Premises
4.2 Equipment
5 Documentation
6 Production
7 Quality Control
9 Internal audit
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1 General information on the manufacturer
Note: If there is multiple manufacturing places (addresses), write down all the places
1.1.3 Contact information of the manufacturer including 24 hrs. telephone number of the contact
Name and title of the contact personnel: □□, Director of ■■ Department, (Supervisor for Drug
Manufacture)
E-mail: [email protected]
Telephone number for contact of business hours: xxx-xxx-xxxx (staff ’s cell phone number, TEL number of
1.1.4 Identification number of the site as e.g. GPS details, D-U-N-S (Data Universal Numbering System)
Number (a unique identification number provided by Dun & Bradstreet) of the site, or any other
1.2 Authorized pharmaceutical manufacturing activities of the site including those from foreign regulatory
authorities
Photocopy of the valid manufacturing authorization issued by the relevant competent authority: See
Appendix 1.
1.2.2 Brief description of manufacture, import, export, distribution and other activities as authorized by
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(1) Domestic: License for Drug Manufacture: API, intermediates for API, non-sterile dosage
(2) Country A: Submitted Drug Establishment Registration to FDA. Drug substance and non-
sterile dosage form manufacturing processes, (submitted notification for the manufacture of
export only drugs including APIs and dosage forms to the Japanese Authorities)
(3) Country B: Submitted notification for the manufacture of export only drugs for APIs (for
1.2.4 List of GMP Inspections of the site within the last 5 years
Copies of current GMP certificates for the products manufactured at this site are given in Appendix 3.
Medical devices
Cosmetics
Insecticides, herbicides
[If applicable]
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2 Quality management system of the manufacturer
2.1.1 Brief description of the quality management system run by the company and reference to the
standards used
The quality management system of ○○ Co., Ltd. □□ Plant is established referring to Ministerial Ordinance on
Standards for Manufacturing Control and Quality Control for Drugs and Quasi-drugs (GMP Ordinance),
relevant regulations/notifications, Current Good Manufacturing Practices Regulations in the US (cGMP) and
PIC/S GMP GUIDE, Quality Manual of ○○ Co. Ltd. □□ Plant serves as the highest level document in
the document system of the site, and various written standards and procedures have been prepared under
this manual.
These documents include quality policy, quality management organization, document control, personnel
qualifications/hygiene control/education & training, manufacturing control, quality control, hygiene control
control, deviation control, handling of quality information and quality defects, etc., recall procedure, self-
The organization related to the quality management system at this manufacturing site is shown in Appendix
5: GMP Organization Chart of ○○ Co., Ltd. □□ Plant. Senior management and other management are
Head of Quality Assurance supervises activities related to manufacturing control and quality control, to
ensure appropriate and smooth conduct of such activities. Head of Quality Assurance is responsible for
change control, deviation control, handling of quality information and quality defects, etc., product recall, and
2.1.3 Information of activities for which the site is accredited and certified
This manufacturing plant isISO-9001certified. Photocopy of the certificate is given in Appendix 6.
ISO-9001
Date of certification:
Scope of certification:
2.2.1 Detailed description of qualification requirements (education and work experience) of the Authorized
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Person(s) responsible for batch certification and releasing procedures
Chapter ○ of the Quality Control Standards sets forth the site procedure for appointment of
personnel responsible for batch certification and releasing. Personnel having actual experience of
quality assurance or quality control for not less than ○ years and having received education/training
on the Law on Securing Quality, Efficacy and Safety of Products Including Pharmaceutical and
Medical Device, GMP Ordinance and other relevant regulations are appointed by the head of Quality
Assurance .
(1) Upon completion of manufacture of a lot of the product, the Quality Assurance Department will
review the batch manufacturing records including the packaging process and submits the results of
(2) The Quality Control Department will review the batch test/inspection records and submits the
results of review (batch quality control record) to the staff in charge of release decision.
(3) The Authorized Person will review the batch manufacturing records, batch manufacturing control
records, batch test/inspection records and batch quality control records and enters the results of
(4) Please describe if a computerized system is used to control the release, the results of release of
all the starting materials and packaging materials used are controlled with the computerized □□
system. The system is designed to alarm any OOS found to the Quality Assurance Department. The
staff at the Quality Assurance Department confirms absence of any such event with the □□ system
and records the results of such confirmation in the product releasing document.
(5) If the staff at the Quality Assurance Department finds a description in the manufacturing records
or the test/inspection records, of any change control or deviation control possibly affect to the lot
concerned, or if the staff finds such an event in the □□ system even when no relevant description is
found in the manufacturing records nor test/inspection records, it is required for the staff to evaluate
the influence of such an event on releasing the lot concerned and to enter such evaluation results
(6) If the Authorized Person judges absence of any problematic finding affecting to release of the lot
concerned as the results of the reviews mentioned above, he/she should enter the judgment into the
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(7) The Authorized Person will enter the release judgment into the computerized ■■ system. Start of
distribution operation for any batch of product prior to the status change into "released" in the ■■
(8) Statement on whether the control strategy employs Process Analytical Technology (PAT) and /or
2.3.1 A brief summary of the establishment/knowledge of supply chain and the external audit program
Agreements with the marketing authorization holders relating to the management of supply chain are
managed in accordance with the procedure of each marketing authorization holder and are reviewed
Selection and approval of suppliers and contractors as well as management of the approved suppliers
and contractors is done by classifying each supplier and contractor according to the results of
assessment of the risks of the raw materials and packaging materials to product quality. Details of
the management to be done in each class are defined in the procedure. Audits will be carried out at
the time of selection and on-going bases thereafter. On-site or desk top audit is selected depending on
2.3.2 Brief description of the qualification system of contractors manufacturers of API and other critical
materials suppliers
contractors/suppliers are carried out in accordance with the procedure described above 2.3.1.
However, evaluation of API supplier is done by reviewing the audit report received from the
2.3.3 Measures taken to ensure that products manufactured are compliant with TSE (Transmissible
Note: If the product is exported to other country, describe the conformance to such exported country's
Raw materials used for the manufacture of the product A in this plant are confirmed to comply with
the Japanese Standard for Biological Ingredients and their handling are controlled in accordance
with the standard. Also the product A is exported to the country A, the plant are also confrimed to
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cmply with the country A Standard for Biological Ingridents "Guideline for TSE", and their handling
2.3.4 Measures adopted where counterfeit/falsified products, bulk products (i.e. unpacked tablets), active
The suspected product should be immediately segregated into quarantine status and the unit that
detected it issues a deviation report in accordance with the deviation handling procedure. Subsequent steps
should be taken in accordance with the same procedure, while investigation should be conducted to check
existence of the same problem in other lots and confirm the range of affected lots. If counterfeit/falsified
product is identified, such event should be immediately notified to the marketing authorization holder and
2.3.5 Use of outside scientific, analytical or other technical assistance in relation to manufacture and
analysis
No technical assistance has been given from outside institution concerning manufacture or analysis.
The analytical methods for the products being manufactured at this manufacturing site have been
developed at the research laboratory of our company or other company and transferred to this site.
Primary and secondary reference materials used for analysis have been supplied from those research
laboratories.
2.3.6 List of contract manufacturers and laboratories including the addresses and contact information and
flow charts of supply chains for outsourced manufacturing and Quality Control activities
A part of analytical work is contracted to outside analytical laboratories. A part of the manufacturing
between us and the contractors, and outline of the contracted activities are shown in Appendix 4.
One or combination of the following methodologies is used for each situation of risk assessment
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Risk ranking and filtering
At this manufacturing site, QRM is applied, in accordance with the policy of ○○ Co., Ltd., to the entire
life cycle of the products to control the risk to the efficacy, safety and quality of the products in all
GMP-related fields. Therefore, QRM is applied also to the entire supply chain, including supply of
Quality Assurance Department is responsible for product quality review and approval.
(i) A review of starting materials including packaging materials used in the product, especially those from
new sources and in particular the review of supply chain traceability of active substances;
(iii) A review of all batches that failed to meet established specification(s) and their investigation;
(iv) A review of all significant deviations or non-conformances, their related investigations, and the
(v) A review of all changes carried out to the processes or analytical methods;
(vi) A review of Marketing Authorization variations submitted, granted or refused, including those for third
(vii) A review of the results of the stability monitoring programme and any adverse trends;
(viii) A review of all quality-related returns, complaints and recalls and the investigations performed at the
time;
(ix) A review of adequacy of any other previous product process or equipment corrective actions;
(x) For new Marketing Authorizations and variations to Marketing Authorizations, a review of post-
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marketing commitments;
(xi) The qualification status of relevant equipment and utilities, e.g. HVAC, water, compressed gases, etc;
(xii) A review of any contractual arrangements as defined in Chapter 7 to ensure that they are up to date.
Items on which the necessity of improvements identified, relevant department prepare corrective action plan
in accordance with the product quality review procedure and submits the plan to the Quality Assurance
Department, where adequacy of the plan is evaluated. The status of implementation of corrective action is
checked during internal audit, and it is also evaluated at the next product quality review. Trend analysis is
done by converting the reviewed data into graphs as needed. If the number of lots manufactured during the
review period is too small, the results in the preceding year(s) are added for review as needed.
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3 Personnel
Production: n=○
Purchasing/warehouse: n=○
Engineering: n=○
Total: n=○
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4 Premises and Equipment
4.1 Premises
Manufacturing facility: Building No. 1 (For EU: manufacture of API and intermediates for API)
Building No. 4 (For Japan: manufacture of API and intermediates for API)
Building
Building No. 3 Building No. 4
No. 5
Building No. 6
Building No. 2
Building No. 1
Building for
Building No. 7
100 m control, etc.
See Appendix 6
Appendix 6-1 (Building No. 1 lay outs, room classification , pressure differential drawing)
Appendix 6-2 (Building No. 2 lay outs, room classification, pressure differential drawing)
Appendix 6-3 (Building No. 3lay outs, room classification, pressure differential drawing)
Appendix 6-4 (Building No. 4lay outs, room classification, pressure differential drawing)
See Appendix 6
Appendix 6-5 (Building No. 5 lay outs, room classification of sampling area, pressure differential
4.1.1 Brief description of heating, ventilation and air conditioning (HVAC) systems
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4.1.1.1 Cleanliness of the rooms within the facilities of this site is classified into 6 grades.
(2) Semi-controlled area: Air conditioning without high grade filter, no particulate/microbe
monitoring
Areas (3) through (6) are controlled in accordance with PIC/S GMP Guidelines Annex 1.
Manufacturing area
Temperature/humidity control is not required for all the raw materials, intermediates or finished
products handled at this manufacturing site. However, in view of the convenience of the operators,
Storage area
Storage area for materials and products to be stored at room temperature is controlled at 1-30°C.
Materials and products to be stored in a refrigerated condition are stored in the rooms or refrigerators
However, samples for stability tests are stored in the rooms or chambers where temperature and
Reference and retention samples are stored in areas of ambient condition, and monitoring of
Pressure differentials with the adjacent different grade rooms in cleanliness-controlled areas such as
Pressure differential is set and controlled so that air flow from lower grade area to higher grade area
Some areas require containment, and an example of the pressure differential cascade is; surrounding
Air change rate is controlled only in the classified area, and in accordance with PIC/S GMP Guidelines
Annex 1. Air is usually recycled in ○○%. In the areas where organic solvents are handled, 100% fresh
air is supplied and the air is exhausted to the environment in accordance with the environmental
standards.
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4.1.2 Brief description of water systems
Three types of water (tap water supplied by local government, purified water and water for injection)
are used at this manufacturing site. Tap water complies with the water quality standards provided
by a Ministerial Ordinance issued by Ministry of Health, Labor and Welfare pursuant to Article 4
Paragraph 2 of the Water Supply Act (Law No. 171 in 1957). Purified water is montyly sanitized by
hot water and WFI is weekly steriled by steam. Purified water and water for injection comply with
the Japanese Pharmacopeia. A schematic diagram of each water system is given in Appendix 7.
Other utilities used for manufacture at this manufacturing site are steam, compressed air and
nitrogen gas.
Two types of steam (industrial steam for heating and pure steam generated from purified water) are
used. Compressed air is prepared by compression with an oil-less compressor and supplied through
Nitrogen gas is prepared from liquid nitrogen. As needed, it is supplied through a 0.2 μ filter.
4.2 Equipment
Major production and control laboratory equipment are listed in Appendix 8. Critical pieces of
Cleaning and sanitation of product contact surfaces is conducted routinely in accordance with the
procedure. Master cleaning instructions and records have been established through cleaning
validation.
There are two types of equipment in this manufacturing site regarding the cleaning methods, manual
cleaning and CIP/SIP. Manually cleaned equipment are either (1) rinsed with water after washing
The computerized system XXX is used at this manufacturing site. This system is used for integrated
(3) Laboratory control (including release of raw materials, intermediates and finished products)
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This system is validated and controlled in accordance with “Guideline on Management of
Computerized Systems for Marketing Authorization Holders and Manufacturers of Drugs and Quasi-
drugs.”
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5 Documentation
Two types of documentation systems (electronic system and paper-based system) are used at this
manufacturing site. Electronic system is applied to the documents of standards and procedures,
Paper-based control is applied to records. Electronically controlled blank forms are printed out by
the personnel having access right to the electronic system and issued to workers in accordance with
the procedure. The completed record form will be reviewed by the supervisor in accordance with the
Documents and records are stored in-house and off-site archiving is used.
Off-site Storage:●● storage Address:○○ Prefecture ∆∆ City ×× Town.
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6 Production
Non-sterile API, solid dosage forms and injectables as described in Section 1.2.4.
6.1.2 Types of investigational medicinal products (IMPs) being manufactured at this site
6.1.3 Toxic or hazardous substances handled (e.g. with high pharmacological activity and/or with
sensitizing properties)
Of the products listed in Appendix 2, two (∆∆ and □□) have high pharmacological activity. API and
dosage forms are manufactured for both of them. No highly sensitizing substance has been handled.
The two products mentioned above (ᇞᇞ and □□) are manufactured under campaign basis at the same
containment facility. Each equipment within this facility is fitted with CIP/SIP function, and
cleaning between batches within a campaign and cleaning at product switching has been validated.
Example A
Example B
Product ○○ is using PAT, in accordance with the procedure ···.(describe general statement of the
relevant technology, and associated computerized systems)
Process validation is carried out in accordance with the validation procedure to confirm that the defined
materials, equipment and manufacturing procedure, critical process parameters, equipment cleaning
For validation at the time of introducing a new product into routine manufacture or at the time of change in
facility/process, a master plan is prepared for such product or project and individual validation plan for each
After successful completion of initial validation, periodical revalidation should be conducted as the product’s
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For the processes or process parameters where periodical revalidation is required by some guidelines such
as sterility-related parameters, periodical revalidation studies are carried out in accordance with the
guidelines. On the other processes or parameters, if the product quality review demonstrate that the
processes are under control, additional re-validation studies are not done, and a revalidation report
A deviation report is issued upon detection of OOS or deviation from process parameters. Then, decision
about the need of reprocessing and reworking will be made on the basis of the results of risk assessment
The reprocessed or reworked lot should be subjected to the product quality review and added to the stability
6.3.1 Arrangements for the handling of starting materials, packaging materials, bulk and finished products
Upon arrival of raw materials at the warehouse, warehouse personnel check the label, appearance,
quantity delivered, etc. and enter information into the computerized system for warehouse control. The
raw materials will be stored as “under quarantine” in the storage space. Upon completion of satisfactory
sampling and test by the Quality Control Department, the status of the materials is changed into
“released” by the Quality Control Department and they will be able to be taken out of the warehouse to be
used for processing.
Upon completion of manufacture of a batch of product, the batch information is entered into the
warehouse control system. The warehouse staff are not able to take out the lot from the warehouse control
system before the status is changed into “released” by the authorized person or the quarantine status in
If raw materials or finished products failed the test and inspection, status of “rejected,” is assigned
to the batch in the computerized system. The batch in this status is retrieved from the storage
immediately and a label “rejected” is attached to them. Then, the batch is segregated into the locked
rejected material area in the raw material warehouse or rejected product area in the product
warehouse. After that, the rejected raw materials are returned to the supplier, and the rejected
All the events of raw material or finished product rejection are subjected to OOS procedure, and
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necessary CAPAs are implemented, according to the deviation handling procedure.
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7 Quality control
The Quality Control Department of this manufacturing site conducts chemical and microbiological
tests of raw materials, other materials used for manufacture (e.g., microbe retentive filter),
intermediates, finished products, stability samples, etc., and maintain storage of the stability
samples, reference and retention samples. In-process test is conducted by the manufacturing
department staff qualified by the Quality Control Department, using the testing methods checked
by the Quality Control Department and approved by the Quality Assurance Department.
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8. Distribution, complaints, product defects and recalls
8.1.1. Types (wholesale license holders, manufacturing license holders, etc.) and locations of the companies
The destination of delivery and the allocation of responsibility for transport of API, bulk products
and finished products distributed from this manufacturing site are decided in the agreement with
ABC-Pharma. Co., Ltd., License Holder in the USA, ∆∆ City, ○○ State, USA
8.1.2 Description of the system used to verify that each customer/recipient is legally entitled to receive
8.1.3 Brief description of the system to ensure appropriate environmental conditions during transit, e.g.
temperature monitoring/control
In accordance with the agreement with the marketing authorization holder, at the time of loading
the products onto the truck, a data logger for recording temperature should be attached to the
products requiring temperature control. The recipient is required, under the agreement, to check
the data logger that the temperature has been within the predestinated range. Notification should
be made only when any deviation is detected. Absence of such notification means that the
In case where the manufacturing site assumes the responsibility for transport, education/training
(including temperature control) should be provided to drivers under an agreement with the
transportation company.
8.1.4 Arrangements for product distribution and methods by which product traceability is maintained
In case where the manufacturing site assumes the responsibility for transport, a written report in
the predefined form is sent from the transportation company to the warehouse staff in this site upon
8.1.5 Measures taken to prevent manufacturers/products to fall in the illegal supply chain
Monitor cameras have been installed at the product warehouse of this manufacturing site, and 24
hours security control is provided. The warehouse staff check the report from the driver described
in Section 8.1.4 and the notification of receipt issued by the recipient to confirm that correct delivery
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8.2 Complaints, product defects and recalls
Brief description of the system for handling complaints, product defects and recalls
The information related to product quality notified from the marketing authorization holders is
transmitted to the Quality Assurance Department in accordance with the quality agreement and
handled according to the procedure in cooperation with other departments related to the event. . If
this manufacturing site is responsible to the quality defect, corrective/preventive actions will be
Recall
If the marketing authorization holder judges that recall of the product is necessary as the result of
the above information, the Quality Assurance Department will take necessary actions and record
The products returned to this manufacturing site as the result of recall will be segregated
9. Internal audit
The Quality Assurance Department is responsible for preparing inspection plan, its conduct, and
preparation of reports and follow-up of observed issues. These actions are taken and recorded in cooperation
The scope of inspection covers all units described in the organization chart (Appendix 5). An annual plan
of self-inspection covering all departments once a year is prepared and carried out according to the plan.
Internal audit is carried out by the personnel of this manufacturing site qualified by the Quality Control
Department. Internal audit is carried out by a team composed of multiple qualified personnel. The
internal audit team should not include any staff of the department being inspected.
The inspection report is delivered to the inspected department and the Plant Manager after approval by
the Quality Assurance Department. If any observation is pointed out, a corrective action plan for such issue
will be submitted from the inspected department to the Quality Assurance Department and it is also
delivered to the Plant Manager. The corrective action plan is followed by the Quality Assurance Department
until all the actions are completed. The outline of these steps is subjected to the Management Review.
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API and Intermediates for API(API Intermediate○○○○○)
intermediates for API Intermediates for API not falling under the category of chemically
synthesized highly sensitizing substances or highly physiologically active
substances (manufactured in non-dedicated area)
API (API△△△△△、API□□□□□□)
1. highly pharmacologically active substances (all are chemically
synthesized substances; two items with cytotoxicity are manufactured under
campaign basis in the area manufacturing only these two items)
These items are manufactured also for export.
2. Chemically synthesized API other than those listed above (manufactured
in the shared areas) (API●●●●●●)
Solid dosage forms Tablets (uncoated tablets▲▲▲▲▲, coated tablets■■■■■) and capsules
( ○ △ ○ △ ○ △ ) are manufactured up to the process of secondary
packaging. No modified release product is now being manufactured.
Injectables Liquids [vials △ □ △ □ △ (either by aseptic processing or terminal
sterilization)] and syringes●▲●▲●▲ (aseptic processing)] and freeze-
dried forms (vials) □○□○□○are being manufactured up to the secondary
packaging.
Two of the liquids have high pharmacological activity, and both of them are
manufactured under campaign basis by aseptic process in the area dedicated
for the manufacture of these two products.
Appendix 4 List of contract manufacturers and laboratories including the addresses and contact
Contract laboratories
TEL: XXX-XXX-XXX
TEL: YYY-YYY-YYY
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Contact information: ○○ ○○, Manager of XX Section
Authorised Person
Quality Assurance Department
Director
(Supervisor for Drug Manufacture)
Staff in charge of quality
assurance
Head of Technical
Development Unit
Head of Purchasing/Warhouse/Delivery
Unit
Head of
Engineering Unit
Lay out of Manufacturing Facility Building No. ○ , room classification in the building, pressure differential
drawing
(Note) The drawing should include environmental classification, pressure differential, cleanliness
classification of each room and manufacturing activity in it (e.g., blending, filling, storage, and packaging).
Specific areas handling highly sensitizing substances or highly pharmacologically active substances also need
to be shown clearly.
Lay out of Warehouse Building No. ○ , room classification of sampling area, pressure differential drawing,
(Note) Specific areas handling materials with high toxicity, hazardous materials, highly sensitizing
substances and highly pharmacologically active substances also need to be shown clearly.
(1) Tap water (outline of the system within the site beginning from the entrance of piping into the
manufacturing site. Schematic diagram showing storage tanks, branching routes, sampling points, etc.)
(2) Purified water (schematic diagrams, showing the source water inlet, purification equipment such as
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activated carbon filtration column, ion exchanger/RO filter/UF filter/electro dialyzer, storage tank
(including vent filter), pumps, piping to the use points, heat exchanger, in-line thermometer/conductivity
(3) WFI (similar to the above-mentioned purified water system; pretreatment is not needed if purified
equipment
● xxxxL reactor
Building No. 1
● xx type dryer
● xx type blender
● xx type mill
● xx type blender
● Wet granulator
● xx type granulator
Building No. 2
● xx type dryer
● Tableting machine
● Cartoning machine
● Tunnel sterilizer
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● Syringe filling machine
● Cartoning machine
equipm
ent
● FTIR
● pH meter
Chemical Test Room
Building No. 6
● Gas chromatograph
● Elemental analyzer
● Incubator
● Incubator
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