Key Metrics for GMP Training in Pharmaceutical Systems: Leading & Lagging Indicators

When thinking about the training program you can add the Kilpatrick model to the mix and build from there. This allows a view across the training system to drive for an effective training program.

GMP Training Metrics Framework Aligned with Kirkpatrick’s Model

Kirkpatrick LevelCategoryMetric TypeExamplePurposeData SourceRegulatory Alignment
Level 1: ReactionKPILeading% Training Satisfaction Surveys CompletedMeasures engagement and perceived relevance of GMP trainingLMS (Learning Management System)ICH Q10 Section 2.7 (Training Effectiveness)
KRILeading% Surveys with Negative Feedback (<70%)Identifies risk of disengagement or poor training designSurvey ToolsFDA Quality Metrics Reporting (2025 Draft)
KBILeadingParticipation in Post-Training FeedbackEncourages proactive communication about training gapsAttendance LogsEU GMP Chapter 2 (Personnel Training)
Level 2: LearningKPILeadingPre/Post-Training Quiz Pass Rate (≥90%)Validates knowledge retention of GMP principlesAssessment Software21 CFR 211.25 (Training Requirements)
KRILeading% Trainees Requiring Remediation (>15%)Predicts future compliance risks due to knowledge gapsLMS Remediation ReportsFDA Warning Letters (Training Deficiencies)
KBILaggingReduction in Knowledge Assessment RetakesValidates long-term retention of GMP conceptsTraining RecordsICH Q7 Section 2.12 (Training Documentation)
Level 3: BehaviorKPILeadingObserved GMP Compliance Rate During AuditsMeasures real-time application of training in daily workflowsAudit ChecklistsFDA 21 CFR 211 (cGMP Compliance)
KRILeadingNear-Miss Reports Linked to Training GapsIdentifies emerging behavioral risks before incidents occurQMS (Quality Management System)ISO 9001:2015 Clause 10.2 (Nonconformity)
KBILeadingFrequency of Peer-to-Peer Knowledge SharingEncourages a culture of continuous learning and collaborationMeeting LogsICH Q10 Section 3.2.3 (Knowledge Management)
Level 4: ResultsKPILagging% Reduction in Repeat Deviations Post-TrainingQuantifies training’s impact on operational qualityDeviation Management SystemsFDA Quality Metrics (Batch Rejection Rate)
KRILaggingAudit Findings Related to Training EffectivenessReflects systemic training failures impacting complianceRegulatory Audit ReportsEU GMP Annex 15 (Qualification & Validation)
KBILaggingEmployee TurnoverAssesses cultural impact of training on staff retentionHR RecordsICH Q10 Section 1.5 (Management Responsibility)

Kirkpatrick Model Integration

  1. Level 1 (Reaction):
  • Leading KPI: Track survey completion to ensure trainees perceive value in GMP content.
  • Leading KRI: Flag facilities with >30% negative feedback for immediate remediation .
  1. Level 2 (Learning):
  • Leading KPI: Require ≥90% quiz pass rates for high-risk roles (e.g., aseptic operators) .
  • Lagging KBI: Retake rates >20% trigger refresher courses under EU GMP Chapter 3 .
  1. Level 3 (Behavior):
  • Leading KPI: <95% compliance during audits mandates retraining per 21 CFR 211.25 .
  • Leading KRI: >5 near-misses/month linked to training gaps violates FDA’s “state of control” .
  1. Level 4 (Results):
  • Lagging KPI: <10% reduction in deviations triggers CAPA under ICH Q10 Section 4.3 .
  • Lagging KRI: Audit findings >3/year require FDA-mandated QMS reviews .

Regulatory & Strategic Alignment

  • FDA Quality Metrics: Level 4 KPIs (e.g., deviation reduction) align with FDA’s 2025 focus on “sustainable compliance” .
  • ICH Q10: Level 3 KBIs (peer knowledge sharing) support “continual improvement of process performance” .
  • EU GMP: Level 2 KRIs (remediation rates) enforce Annex 11’s electronic training documentation requirements .

By integrating Kirkpatrick’s levels with GMP training metrics, organizations bridge knowledge acquisition to measurable quality outcomes while meeting global regulatory expectations.

Key Metrics for Pharmaceutical Change Control: Leading & Lagging Indicators

CategoryMetric TypeExamplePurposeRegulatory Alignment
KPILeading% Change Requests with Completed Risk AssessmentsPredicts compliance with FDA 21 CFR 211.100 (process control)FDA 21 CFR 211, ICH Q10, ICH Q9
LaggingAverage Time to Close Change RequestsValidates efficiency of change implementation (EudraLex Annex 15)EU GMP Annex 15
KRILeadingUnresolved CAPAs Linked to Change RequestsIdentifies systemic risks before deviations occur (FDA Warning Letters)21 CFR 211.22, ICH Q7
LaggingRepeat Deviations Post-ChangeReflects failure to address root causes (FDA 483 Observations)21 CFR 211.192
KBILeadingCross-Functional Review Participation RateEncourages proactive collaboration in change evaluationICH Q10 Section 3.2.3
LaggingReduction in Documentation Errors Post-TrainingValidates effectiveness of staff competency programsEU 1252/2014 Article 14

Key Performance Indicators (KPIs)

  • Leading KPI:
  • Change Requests with Completed Risk Assessments: Measures proactive compliance with FDA requirements for risk-based change evaluation. A rate <90% triggers quality reviews.
  • Lagging KPI:
  • Time to Close Changes: Benchmarks against EMA’s 30-day resolution expectation for critical changes. Prolonged closure (>45 days) indicates process bottlenecks.

Key Risk Indicators (KRIs)

  • Leading KRI:
  • Unresolved CAPAs: Predicts validation gaps; >5 open CAPAs per change violates FDA’s “state of control” mandate.
  • Lagging KRI:
  • Repeat Deviations: >3 repeat deviations quarterly triggers mandatory revalidation per FDA 21 CFR 211.180.

Key Behavioral Indicators (KBIs)

  • Leading KBI:
  • Review Participation: <80% cross-functional attendance violates ICH Q10’s “integrated team” expectation.
  • Lagging KBI:
  • Documentation Errors: Post-training error reduction <30% prompts requalification under EU GMP Chapter 4.

Implementation Guidance

Align with Regulatory Thresholds: Set leading KPI targets using FDA’s 2025 draft guidance: ≥95% risk assessment completion for high-impact changes.

Automate Tracking: Integrate metrics with eQMS software to monitor CAPA aging (leading KRI) and deviation trends (lagging KRI) in real time.

Link to Training: Tie lagging KBIs to annual GMP refresher courses, as required by EU 1252/2014 Article 14.


    Why It Matters:
    Leading metrics enable proactive mitigation of change-related risks (e.g., unresolved CAPAs predicting audit failures), while lagging metrics validate adherence to FDA’s lifecycle approach for process validation. Balancing both ensures compliance with 21 CFR 211’s “state of control” mandate while fostering continuous improvement.

    Navigating Metrics in Quality Management: Leading vs. Lagging Indicators, KPIs, KRIs, KBIs, and Their Role in OKRs

    Understanding how to measure success and risk is critical for organizations aiming to achieve strategic objectives. As we develop Quality Plans and Metric Plans it is important to explore the nuances of leading and lagging metrics, define Key Performance Indicators (KPIs), Key Behavioral Indicators (KBIs), and Key Risk Indicators (KRIs), and explains how these concepts intersect with Objectives and Key Results (OKRs).

    Leading vs. Lagging Metrics: A Foundation

    Leading metrics predict future outcomes by measuring activities that drive results. They are proactive, forward-looking, and enable real-time adjustments. For example, tracking employee training completion rates (leading) can predict fewer operational errors.

    Lagging metrics reflect historical performance, confirming whether quality objectives were achieved. They are reactive and often tied to outcomes like batch rejection rates or the number of product recalls. For example, in a pharmaceutical quality system, lagging metrics might include the annual number of regulatory observations, the percentage of batches released on time, or the rate of customer complaints related to product quality. These metrics provide a retrospective view of the quality system’s effectiveness, allowing organizations to assess their performance against predetermined quality goals and industry standards. They offer limited opportunities for mid-course corrections

    The interplay between leading and lagging metrics ensures organizations balance anticipation of future performance with accountability for past results.

    Defining KPIs, KRIs, and KBIs

    Key Performance Indicators (KPIs)

    KPIs measure progress toward Quality System goals. They are outcome-focused and often tied to strategic objectives.

    • Leading KPI Example: Process Capability Index (Cpk) – This measures how well a process can produce output within specification limits. A higher Cpk could indicate fewer products requiring disposition.
    • Lagging KPI Example: Cost of Poor Quality (COPQ) -The total cost associated with products that don’t meet quality standards, including testing and disposition cost.

    Key Risk Indicators (KRIs)

    KRIs monitor risks that could derail objectives. They act as early warning systems for potential threats. Leading KRIs should trigger risk assessments and/or pre-defined corrections when thresholds are breached.

    • Leading KRI Example: Unresolved CAPAs (Corrective and Preventive Actions) – Tracks open corrective actions for past deviations. A rising number signals unresolved systemic issues that could lead to recurrence
    • Lagging KRI Example: Repeat Deviation Frequency – Tracks recurring deviations of the same type. Highlights ineffective CAPAs or systemic weaknesses

    Key Behavioral Indicators (KBIs)

    KBIs track employee actions and cultural alignment. They link behaviors to Quality System outcomes.

    • Leading KBI Example: Frequency of safety protocol adherence (predicts fewer workplace accidents).
    • Lagging KBI Example: Employee turnover rate (reflects past cultural challenges).

    Applying Leading and Lagging Metrics to KPIs, KRIs, and KBIs

    Each metric type can be mapped to leading or lagging dimensions:

    • KPIs: Leading KPIs drive action while lagging KPIs validate results
    • KRIs: Leading KRIs identify emerging risks while lagging KRIs analyze past incidents
    • KBIs: Leading KBIs encourage desired behaviors while lagging KBIs assess outcomes

    Oversight Framework for the Validated State

    An example of applying this for the FUSE(P) program.

    CategoryMetric TypeFDA-Aligned ExamplePurposeData Source
    KPILeading% completion of Stage 3 CPV protocolsProactively ensures continued process verification aligns with validation master plans Validation tracking systems
    LaggingAnnual audit findings related to validation driftConfirms adherence to regulator’s “state of control” requirementsInternal/regulatory audit reports
    KRILeadingOpen CAPAs linked to FUSe(P) validation gapsIdentifies unresolved systemic risks affecting process robustness Quality management systems (QMS)
    LaggingRepeat deviations in validated batchesReflects failure to address root causes post-validation Deviation management systems
    KBILeadingCross-functional review of process monitoring trendsEncourages proactive behavior to maintain validation stateMeeting minutes, action logs
    LaggingReduction in human errors during requalificationValidates effectiveness of training/behavioral controlsTraining records, deviation reports

    This framework operationalizes a focus on data-driven, science-based programs while closing gaps cited in recent Warning Letters.


    Goals vs. OKRs: Alignment with Metrics

    Goals are broad, aspirational targets (e.g., “Improve product quality”). OKRs (Objectives and Key Results) break goals into actionable, measurable components:

    • Objective: Reduce manufacturing defects.
    • Key Results:
      • Decrease batch rejection rate from 5% to 2% (lagging KPI).
      • Train 100% of production staff on updated protocols by Q2 (leading KPI).
      • Reduce repeat deviations by 30% (lagging KRI).

    KPIs, KRIs, and KBIs operationalize OKRs by quantifying progress and risks. For instance, a leading KRI like “number of open CAPAs” (Corrective and Preventive Actions) informs whether the OKR to reduce defects is on track.


    More Pharmaceutical Quality System Examples

    Leading Metrics

    • KPI: Percentage of staff completing GMP training (predicts adherence to quality standards).
    • KRI: Number of unresolved deviations in the CAPA system (predicts compliance risks).
    • KBI: Daily equipment calibration checks (predicts fewer production errors).

    Lagging Metrics

    • KPI: Batch rejection rate due to contamination (confirms quality failures).
    • KRI: Regulatory audit findings (reflects past non-compliance).
    • KBI: Employee turnover in quality assurance roles (indicates cultural or procedural issues).

    Metric TypePurposeLeading ExampleLagging Example
    KPIMeasure performance outcomesTraining completion rateQuarterly profit margin
    KRIMonitor risksOpen CAPAsRegulatory violations
    KBITrack employee behaviorsSafety protocol adherence frequencyEmployee turnover rate

    Building Effective Metrics

    1. Align with Strategy: Ensure metrics tie to Quality System goals. For OKRs, select KPIs/KRIs that directly map to key results.
    2. Balance Leading and Lagging: Use leading indicators to drive proactive adjustments and lagging indicators to validate outcomes.
    3. Pharmaceutical Focus: In quality systems, prioritize metrics like right-first-time rate (leading KPI) and repeat deviation rate (lagging KRI) to balance prevention and accountability.

    By integrating KPIs, KRIs, and KBIs into OKRs, organizations create a feedback loop that connects daily actions to long-term success while mitigating risks. This approach transforms abstract goals into measurable, actionable pathways—a critical advantage in regulated industries like pharmaceuticals.

    Understanding these distinctions empowers teams to not only track performance but also shape it proactively, ensuring alignment with both immediate priorities and strategic vision.

    Reducing Subjectivity in Quality Risk Management: Aligning with ICH Q9(R1)

    In a previous post, I discussed how overcoming subjectivity in risk management and decision-making requires fostering a culture of quality and excellence. This is an issue that it is important to continue to evaluate and push for additional improvement.

    The revised ICH Q9(R1) guideline, finalized in January 2023, introduces critical updates to Quality Risk Management (QRM) practices, emphasizing the need to address subjectivity, enhance formality, improve risk-based decision-making, and manage product availability risks. These revisions aim to ensure that QRM processes are more science-driven, knowledge-based, and effective in safeguarding product quality and patient safety. Two years later it is important to continue to build on key strategies for reducing subjectivity in QRM and aligning with the updated requirements.

    Understanding Subjectivity in QRM

    Subjectivity in QRM arises from personal opinions, biases, heuristics, or inconsistent interpretations of risks by stakeholders. This can impact every stage of the QRM process—from hazard identification to risk evaluation and mitigation. The revised ICH Q9(R1) explicitly addresses this issue by introducing a new subsection, “Managing and Minimizing Subjectivity,” which emphasizes that while subjectivity cannot be entirely eliminated, it can be controlled through structured approaches.

    The guideline highlights that subjectivity often stems from poorly designed scoring systems, differing perceptions of hazards and risks among stakeholders, and cognitive biases. To mitigate these challenges, organizations must adopt robust strategies that prioritize scientific knowledge and data-driven decision-making.

    Strategies to Reduce Subjectivity

    Leveraging Knowledge Management

    ICH Q9(R1) underscores the importance of knowledge management as a tool to reduce uncertainty and subjectivity in risk assessments. Effective knowledge management involves systematically capturing, organizing, and applying internal and external knowledge to inform QRM activities. This includes maintaining centralized repositories for technical data, fostering real-time information sharing across teams, and learning from past experiences through structured lessons-learned processes.

    By integrating knowledge management into QRM, organizations can ensure that decisions are based on comprehensive data rather than subjective estimations. For example, using historical data on process performance or supplier reliability can provide objective insights into potential risks.

    To integrate knowledge management (KM) more effectively into quality risk management (QRM), organizations can implement several strategies to ensure decisions are based on comprehensive data rather than subjective estimations:

    Establish Robust Knowledge Repositories

    Create centralized, easily accessible repositories for storing and organizing historical data, lessons learned, and best practices. These repositories should include:

    • Process performance data
    • Supplier reliability metrics
    • Deviation and CAPA records
    • Audit findings and inspection observations
    • Technology transfer documentation

    By maintaining these repositories, organizations can quickly access relevant historical information when conducting risk assessments.

    Implement Knowledge Mapping

    Conduct knowledge mapping exercises to identify key sources of knowledge within the organization. This process helps to:

    Use the resulting knowledge maps to guide risk assessment teams to relevant information and expertise.

    Develop Data Analytics Capabilities

    Invest in data analytics tools and capabilities to extract meaningful insights from historical data. For example:

    • Use statistical process control to identify trends in manufacturing performance
    • Apply machine learning algorithms to predict potential quality issues based on historical patterns
    • Utilize data visualization tools to present complex risk data in an easily understandable format

    These analytics can provide objective, data-driven insights into potential risks and their likelihood of occurrence.

    Integrate KM into QRM Processes

    Embed KM activities directly into QRM processes to ensure consistent use of available knowledge:

    • Include a knowledge gathering step at the beginning of risk assessments
    • Require risk assessment teams to document the sources of knowledge used in their analysis
    • Implement a formal process for capturing new knowledge generated during risk assessments

    This integration helps ensure that all relevant knowledge is considered and that new insights are captured for future use.

    Foster a Knowledge-Sharing Culture

    Encourage a culture of knowledge sharing and collaboration within the organization:

    • Implement mentoring programs to facilitate the transfer of tacit knowledge
    • Establish communities of practice around key risk areas
    • Recognize and reward employees who contribute valuable knowledge to risk management efforts

    By promoting knowledge sharing, organizations can tap into the collective expertise of their workforce to improve risk assessments.

    Implementing Structured Risk-Based Decision-Making

    The revised guideline introduces a dedicated section on risk-based decision-making, emphasizing the need for structured approaches that consider the complexity, uncertainty, and importance of decisions. Organizations should establish clear criteria for decision-making processes, define acceptable risk tolerance levels, and use evidence-based methods to evaluate options.

    Structured decision-making tools can help standardize how risks are assessed and prioritized. Additionally, calibrating expert opinions through formal elicitation techniques can further reduce variability in judgments.

    Addressing Cognitive Biases

    Cognitive biases—such as overconfidence or anchoring—can distort risk assessments and lead to inconsistent outcomes. To address this, organizations should provide training on recognizing common biases and their impact on decision-making. Encouraging diverse perspectives within risk assessment teams can also help counteract individual biases.

    For example, using cross-functional teams ensures that different viewpoints are considered when evaluating risks, leading to more balanced assessments. Regularly reviewing risk assessment outputs for signs of bias or inconsistencies can further enhance objectivity.

    Enhancing Formality in QRM

    ICH Q9(R1) introduces the concept of a “formality continuum,” which aligns the level of effort and documentation with the complexity and significance of the risk being managed. This approach allows organizations to allocate resources effectively by applying less formal methods to lower-risk issues while reserving rigorous processes for high-risk scenarios.

    For instance, routine quality checks may require minimal documentation compared to a comprehensive risk assessment for introducing new manufacturing technologies. By tailoring formality levels appropriately, organizations can ensure consistency while avoiding unnecessary complexity.

    Calibrating Expert Opinions

    We need to recognize the importance of expert knowledge in QRM activities, but also acknowledges the potential for subjectivity and bias in expert judgments. We need to ensure we:

    • Implement formal processes for expert opinion elicitation
    • Use techniques to calibrate expert judgments, especially when estimating probabilities
    • Provide training on common cognitive biases and their impact on risk assessment
    • Employ diverse teams to counteract individual biases
    • Regularly review risk assessment outputs for signs of bias or inconsistencies

    Calibration techniques may include:

    • Structured elicitation protocols that break down complex judgments into more manageable components
    • Feedback and training to help experts align their subjective probability estimates with actual frequencies of events
    • Using multiple experts and aggregating their judgments through methods like Cooke’s classical model
    • Employing facilitation techniques to mitigate groupthink and encourage independent thinking

    By calibrating expert opinions, organizations can leverage valuable expertise while minimizing subjectivity in risk assessments.

    Utilizing Cooke’s Classical Model

    Cooke’s Classical Model is a rigorous method for evaluating and combining expert judgments to quantify uncertainty. Here are the key steps for using the Classical Model to evaluate expert judgment:

    Select and calibrate experts:
      • Choose 5-10 experts in the relevant field
      • Have experts assess uncertain quantities (“calibration questions”) for which true values are known or will be known soon
      • These calibration questions should be from the experts’ domain of expertise
      Elicit expert assessments:
        • Have experts provide probabilistic assessments (usually 5%, 50%, and 95% quantiles) for both calibration questions and questions of interest
        • Document experts’ reasoning and rationales
        Score expert performance:
        • Evaluate experts on two measures:
          a) Statistical accuracy: How well their probabilistic assessments match the true values of calibration questions
          b) Informativeness: How precise and focused their uncertainty ranges are
        Calculate performance-based weights:
          • Derive weights for each expert based on their statistical accuracy and informativeness scores
          • Experts performing poorly on calibration questions receive little or no weight
          Combine expert assessments:
          • Use the performance-based weights to aggregate experts’ judgments on the questions of interest
          • This creates a “Decision Maker” combining the experts’ assessments
          Validate the combined assessment:
          • Evaluate the performance of the weighted combination (“Decision Maker”) using the same scoring as for individual experts
          • Compare to equal-weight combination and best-performing individual experts
          Conduct robustness checks:
          • Perform cross-validation by using subsets of calibration questions to form weights
          • Assess how well performance on calibration questions predicts performance on questions of interest

          The Classical Model aims to create an optimal aggregate assessment that outperforms both equal-weight combinations and individual experts. By using objective performance measures from calibration questions, it provides a scientifically defensible method for evaluating and synthesizing expert judgment under uncertainty.

          Using Data to Support Decisions

          ICH Q9(R1) emphasizes the importance of basing risk management decisions on scientific knowledge and data. The guideline encourages organizations to:

          • Develop robust knowledge management systems to capture and maintain product and process knowledge
          • Create standardized repositories for technical data and information
          • Implement systems to collect and convert data into usable knowledge
          • Gather and analyze relevant data to support risk-based decisions
          • Use quantitative methods where feasible, such as statistical models or predictive analytics

          Specific approaches for using data in QRM may include:

          • Analyzing historical data on process performance, deviations, and quality issues to inform risk assessments
          • Employing statistical process control and process capability analysis to evaluate and monitor risks
          • Utilizing data mining and machine learning techniques to identify patterns and potential risks in large datasets
          • Implementing real-time data monitoring systems to enable proactive risk management
          • Conducting formal data quality assessments to ensure decisions are based on reliable information

          Digitalization and emerging technologies can support data-driven decision making, but remember that validation requirements for these technologies should not be overlooked.

          Improving Risk Assessment Tools

          The design of risk assessment tools plays a critical role in minimizing subjectivity. Tools with well-defined scoring criteria and clear guidance on interpreting results can reduce variability in how risks are evaluated. For example, using quantitative methods where feasible—such as statistical models or predictive analytics—can provide more objective insights compared to qualitative scoring systems.

          Organizations should also validate their tools periodically to ensure they remain fit-for-purpose and aligned with current regulatory expectations.

          Leverage Good Risk Questions

          A well-formulated risk question can significantly help reduce subjectivity in quality risk management (QRM) activities. Here’s how a good risk question contributes to reducing subjectivity:

          Clarity and Focus

          A good risk question provides clarity and focus for the risk assessment process. By clearly defining the scope and context of the risk being evaluated, it helps align all participants on what specifically needs to be assessed. This alignment reduces the potential for individual interpretations and subjective assumptions about the risk scenario.

          Specific and Measurable Terms

          Effective risk questions use specific and measurable terms rather than vague or ambiguous language. For example, instead of asking “What are the risks to product quality?”, a better question might be “What are the potential causes of out-of-specification dissolution results for Product X in the next 6 months?”. The specificity in the latter question helps anchor the assessment in objective, measurable criteria.

          Factual Basis

          A well-crafted risk question encourages the use of factual information and data rather than opinions or guesses. It should prompt the risk assessment team to seek out relevant data, historical information, and scientific knowledge to inform their evaluation. This focus on facts and evidence helps minimize the influence of personal biases and subjective judgments.

          Standardized Approach

          Using a consistent format for risk questions across different assessments promotes a standardized approach to risk identification and analysis. This consistency reduces variability in how risks are framed and evaluated, thereby decreasing the potential for subjective interpretations.

          Objective Criteria

          Good risk questions often incorporate or imply objective criteria for risk evaluation. For instance, a question like “What factors could lead to a deviation from the acceptable range of 5-10% for impurity Y?” sets clear, objective parameters for the assessment, reducing the room for subjective interpretation of what constitutes a significant risk.

          Promotes Structured Thinking

          Well-formulated risk questions encourage structured thinking about potential hazards, their causes, and consequences. This structured approach helps assessors focus on objective factors and causal relationships rather than relying on gut feelings or personal opinions.

          Facilitates Knowledge Utilization

          A good risk question should prompt the assessment team to utilize available knowledge effectively. It encourages the team to draw upon relevant data, past experiences, and scientific understanding, thereby grounding the assessment in objective information rather than subjective impressions.

          By crafting risk questions that embody these characteristics, QRM practitioners can significantly reduce the subjectivity in risk assessments, leading to more reliable, consistent, and scientifically sound risk management decisions.

          Fostering a Culture of Continuous Improvement

          Reducing subjectivity in QRM is an ongoing process that requires a commitment to continuous improvement. Organizations should regularly review their QRM practices to identify areas for enhancement and incorporate feedback from stakeholders. Investing in training programs that build competencies in risk assessment methodologies and decision-making frameworks is essential for sustaining progress.

          Moreover, fostering a culture that values transparency, collaboration, and accountability can empower teams to address subjectivity proactively. Encouraging open discussions about uncertainties or disagreements during risk assessments can lead to more robust outcomes.

          Conclusion

          The revisions introduced in ICH Q9(R1) represent a significant step forward in addressing long-standing challenges associated with subjectivity in QRM. By leveraging knowledge management, implementing structured decision-making processes, addressing cognitive biases, enhancing formality levels appropriately, and improving risk assessment tools, organizations can align their practices with the updated guidelines while ensuring more reliable and science-based outcomes.

          It has been two years, it is long past time be be addressing these in your risk management process and quality system.

          Ultimately, reducing subjectivity not only strengthens compliance with regulatory expectations but also enhances the quality of pharmaceutical products and safeguards patient safety—a goal that lies at the heart of effective Quality Risk Management.

          Timely Equipment/Facility Upgrades

          One of the many fascinating items in the recent Warning Letter to Sanofi is the FDA’s direction to provide a plan to perform “timely technological upgrades to the equipment/facility infrastructure.” This point drives home the point that staying current with technological advancements is crucial for maintaining compliance, improving efficiency, and ensuring product quality. Yet, I think it is fair to say we rarely see it this bluntly put as a requirement.

          One of the many reasons this Warning Letter stands out is that this is (as far as I can tell) the same facility that won the ISPE’s Facility of the Year award in 2020. This means it is still a pretty new facility, and since it is one of the templates that many single-use biotech manufacturing facilities are based on, we had best pay attention. If a failure to maintain a state-of-the-art facility can contribute to this sort of Warning Letter, then many companies had best be paying close attention. There is a lot to unpack and learn here.

          Establishing an Ongoing Technology Platform Process

          To meet regulatory requirements and industry standards, facilities should implement a systematic approach to technological upgrades.

          1. Conduct Regular Assessments

          At least annually, perform comprehensive evaluations of your facility’s equipment, systems, and processes. This assessment should include:

          • Review of equipment performance and maintenance, including equipment effectiveness
          • Analysis of deviation reports and quality issues
          • Evaluation of current technologies against emerging industry standards
          • Assessment of facility design and layout for potential improvements

          This should be captured as part of the FUSE metrics plan and appropriately evaluated as part of quality governance.

          2. Stay Informed on Industry Trends

          Keep abreast of technological advancements in biotech manufacturing at minimum by:

          • Attending industry conferences and workshops
          • Participating in working groups for key consensus standard writers, such as ISPE and ASTM
          • Subscribing to relevant publications and regulatory updates
          • Engaging with equipment vendors and technology providers

          3. Develop a Risk-Based Approach

          Prioritize upgrades based on their potential impact on product quality, patient safety, and regulatory compliance. Utilize living risk assessments to get a sense of where issues are developing. These should be the evolution of the risk management that built the facility.

          4. Create a Technology Roadmap

          Develop a long-term plan for implementing upgrades, considering:

          • Budget constraints and return on investment
          • Regulatory timelines for submissions and approvals
          • Production schedules and potential downtime
          • Integration with existing systems and processes

          5. Implement Change Management Procedures

          Ensure there is a robust change management process in place to ensure that upgrades are implemented safely and effectively. This should include:

          6. Appropriate Verification – Commissioning, Qualification and Validation

          Conduct thorough verification activities to demonstrate that the upgraded equipment or systems meet predetermined specifications and regulatory requirements.

          7. Monitor and Review Performance

          Continuously monitor the performance of upgraded systems and equipment to ensure they meet expectations and comply with cGMP requirements. Conduct periodic reviews to identify any necessary adjustments or further improvements. This is all part of Stage 3 of the FDA’s process validation model focusing on ongoing assurance that the process remains in a state of control during routine commercial manufacture. This stage is designed to:

          • Anticipate and prevent issues before they occur
          • Detect unplanned deviations from the process
          • Identify and correct problems

          Leveraging Advanced Technologies

          To stay ahead of regulatory expectations and industry trends, consider incorporating advanced technologies into your upgrade plans:

          • Single-Use Systems (SUS): Implement disposable components to reduce cleaning and validation requirements while improving flexibility.
          • Modern Microbial Methods (MMM): Implement advanced techniques used in microbiology that offer significant advantages over traditional culture-based methods
          • Process Analytical Technology (PAT): Integrate real-time monitoring and control systems to enhance product quality and process understanding.
          • Data Analytics and Artificial Intelligence: Implement advanced data analysis tools to identify trends, predict maintenance needs, and optimize processes.

          Conclusion

          Maintaining a state-of-the-art biotech facility requires a proactive and systematic approach to technological upgrades. By establishing an ongoing process for identifying and implementing improvements, facilities can ensure compliance with FDA requirements, align with industry standards, and stay competitive in the rapidly evolving biotech landscape.

          Remember that the goal is not just to meet current regulatory expectations but to anticipate future requirements and position your facility at the forefront of biotech manufacturing excellence. By following this comprehensive approach and staying informed on industry developments, you can create a robust, flexible, and compliant manufacturing environment that supports the production of high-quality biopharmaceutical products.