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“OPERATION QUALIFICATION

PROTOCOL (OQ)”

ROTA 940 PA
AMPOULE FILLING & SEALING MACHINE (A3)

FOR
PHARCO PHARMACEUTICAL INDUSTRIES
ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

1- Protocol approval
1.1 Protocol Prepared By: -

Name : Eng. Ahmed Bassiouny


Job Title : Validation & Qualification Engineer
Sign. I Date :
1.2 Protocol Reviewed By: -

Name : Eng. Dina Rabea


Job Title : Validation & Qualification Engineer
Sign. I Date :

1.3 Customer Approval for Documentation of the following Protocol: -

Name Job Title Sign. / Date

Eng. Samar Elroby Qualification Engineer

Eng. Karim Ramadan Mechanical Engineer

Eng. Yasser Dusuki Engineering Division Director

1.4 Personnel Responsible for Execution of Qualification Activities: -

Name Job Title Sign. / Date

Eng. Ahmed Bassiouny Validation & Qualification Engineer

Eng. Dina Rabea Validation & Qualification Engineer

1.5 Customer Approval for Execution of the following Protocol: -

Name Job Title Sign. / Date

Eng. Samar Elroby Qualification Engineer

Eng. Karim Ramadan Mechanical Engineer

Eng. Yasser Dusuki Engineering Division Director

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 1 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

2-Contents

Item No Content of Protocol Page No.

1 Protocol approval 1
2 Contents 2
3 Introduction 3
4 Overview 4
4.1 Scope 4
4.2 Testing Philosophy 4
4.3 Equipment Identification 5
5 Responsibility 6
5.1 GREEN TK company 6
5.2 PHARCO company 6
6 Procedure 7
7 Performing calibration 9
8 Associated documents 10
9 Definitions of terms used in OQ test result sheet 11
10 Test plan 12
11 Test Protocol 13
12 Operational qualification tests 14
13 Job Sheets 35
14 Non-conforming report 36
15 Operation qualification summary report 37
16 Attachment 38

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 2 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

3. Introduction
It is necessary to verify that ROTA 940 PA (A3) conformance to specification in its intended
operational environment.

This is considered at two levels:

Installation Qualification (IQ):

Has the ROTA 940 PA (A3) been built and configured to the agreed technical specification.

Operational Qualification (OQ):

Does the ROTA 940 PA (A3) perform to the agreed functional specification?

Purpose:

This document sets out the operational qualification tests recommended by engineering deviation to
verify the conformity of ROTA 940 PA (A3) to approved technical specification. This plan is design to
guide operational qualification.

The document includes a total package, which may be used to plan, manage, conduct, and document the
operational qualification to the standard required by regulatory bodies.

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 3 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

4 .Overview:-

4.1 Scope: -

The document covers Operation Qualification of the specific SARONGMACHINE, at the production
area.
All components and sub systems of ROTA 940 PA (A3) are included if exceeded in full, a
comprehensive validation of the ROTA 940 PA (A3) can be achieved, as required after initial
commissioning.

4.2Testing Philosophy: -

No testing can be completely exhaustive. The objectives of the test plan is to-achieve a reasonable
level of assurance on every component and sub- system of the ROTA 940 PA (A3) while giving
Particular emphasis to Critical Process Parameters.

All tests are designed to verify the system against unambiguous, documented, pre-determined
acceptance criteria. The protocols are designed to ensure that the testing follows clear, pre-
determined methods approved in advance.

All tests are designed to be conducted by properly authorized personnel, supported by relevant
documentation and test equipment.

Wherever possible the tests are designed to collect all the documentary evidence needed to
retrospectively audit the validity of the results. The procedures call for the test results to be formally
reviewed before being regarded as finally accepted.

As the tests are designed to produce documentary evidence of the results, they can be witnessed at
the review stage. It is left to the discretion of the customer to decide whether to also have the testing
independently witnessed at the time of testing.

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 4 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

4.3 Equipment Identification: -

Manufacture Rota Verpackungstechnik GmbH

Machine S.N. 81

Model R 940 PA

Location Production

Department Ampoules

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 5 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

5:- Responsibilities
Present paragraph identify responsibilities of various parts involved in Qualification
activities.

5.1:- GREEN TK Company

GREEN TK Company will be responsible for the following activities:

(1) Prepare the Qualification Protocol.


(2) To write and review the Qualification Protocol.
(3) To execute the Qualification activities.
(4) To check and collect results into appropriate data collection forms.
(5) To write and review the final Qualification Summery Reports;
Qualification certificate is attached.

5.2:- PHARCO Company

PHARCO Company will be responsible for the following activities:

(1) To manage the revision and the approval of the Qualification Protocol.
(2) To plan the execution of Qualification Protocol.

(3) To supply all necessary assistance to Qualification execution contractor for


the Qualification execution activities.
(4) To approve all qualification tests and the final Qualification Summery Reports.
(5) To manage amendments and deviations, if it is necessary.

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 6 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

6-Procedure
6.1 Preparing a test plan:

The designated ""test manager"" must complete the test plan by:-
1) Identifying all aspects of the Operational Qualification to be covered.
2) Reviewing the verification tests included in this document and ensuring that all OQ
requirements have been included.
3) Designing any "additional" tests needed to meet any OQ requirements not covered by this
standard set of tests, which.
Identifying any tests, which are not required for this machine because they are "Not applicable" or
documentary evidence of conformance already.

A qualified "test approver" who must sign of each protocol sheet as it is approved must approve the
method and acceptance criteria of all protocol in the finalized test plan in advance.

6.2 Conducting approved tests:

The authorized tester using the method section of its protocol must conduct each test. Should
the method be unsuitable then a variation must be documented and authorized by the "test approver"
and the protocol conducted as an additional test. Each test protocol includes statement of the accepted
criteria that must be achieved for the test to be passed. This may the combined result of many test
steps.
The results must be recorded as required by the result section.

Where the result confirm that the expected result has been achieved, the results table will allow for a
clear statement (Yes / Not) of this.
YES will always confirm a satisfactory result
NO will always denote non-conformance

Where the method required the use of a calibrated measuring instrument, the unique identity of the
instrument used must be recorded in the instrument reference section of the protocol and the
reference of the calibration certificate recorded in the document or printout reference section.

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 7 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

6.3 Conforming test compliance:

When the result show that all acceptance criteria have been satisfied. The tester must indicate, writing
YES in the compliance section at the end of each form, then sign and date the section.

Should any acceptance criteria remain not satisfied, the tester must write NO in the compliance
section, sign it not initial the test plan, fill the protocol sheet in the failed tests, and advise the "test
manager" the problem must be resolved and the repeated on a new protocol sheet.

6.4 Reviewing Passed Tests:

When each test has been satisfactory completed an authorized "test reviewer "must review the result
to verify that the test has been properly conducted by authorized personal, and signed off; all the
results are satisfactory; all the required supporting documentation has been identified, signed, dated
and retained. When satisfied that all is in order, the "test reviewer" must sign off the protocol sheet as
reviewed, file it in the reviewed tests, and initial the complete column in the test plan section 6.

6.5 Reviewing failed tests:

When a test has been failed, the "test reviewer" must assess its results or a reviewer group called by
the "test manager".
Three actions are possible:
1) Repeat the test, using a new protocol sheet.
2) Apply a change or modification to the equipment and repeat the test.
3) Abandon the test, and possibly others.
The review shall decide which course of action to take, and in the event of a change or modification,
decide the amount of subsequent re-testing to be done.
The results of this review must be documented in a non-conforming report.

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 8 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

7- Performing calibration

Performing calibration for all parts can be calibrated.


The calibration reports are attached.

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 9 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

8. Associated documents

The following documents have been used during preparation of the test result sheets:

• Wiring diagrams

• Layout

• Control Panel

 The following documents must be available for the tests:

• Operating manual

• Wiring diagram

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 10 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

9. Definition of terms used in OQ test result sheet


All assemblies required for production operation must be active in order to ensure that the OQ tests can be
performed in conformity with the test result sheets. The monitoring functions of the assemblies must be
active, too.
The packaging machine checks its assemblies and starts the referencing procedure if necessary.
The referencing procedure is started automatically after resetting of the faults.
The tests result sheets include some frequently recurring procedures, which will be explained in detail
below.

Term Procedure
All main power switches of the machine are OFF.
Machine switched off
Additional switches for optional devices, e.g. a separate 24 V
power supply are also OFF.

Turn off all main power switches of the machine.


Switch off
machine Turn off additional switches for optional devices, e.g. a separate 24
V power supply.

Turn on all main power switches of the machine.

Reset voltage control

Switch on machine Wait until the Touch Control has started up.

Log on to the Touch Control.

Reset faults

The message "Machine ready to start" appears in the status line.


Machine ready for
production
Production mode is selected.

Machine in production Machine runs in production mode.

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 11 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

10- Test plan


This section gives full available tests. Additional tests may be added at the test manager's discretion.

If the "test manager" assesses that earlier testing has given satisfactory evidence of functional
performance, he may choose to reduce or "Not required" the corresponding standard OQ test to be
done.

The tester must then initial each remaining test as it is completed with satisfactory result.

Test Version Initial


Test title Comments
ref. No. Not required Completed
OQ.1 1 Machine Control Panel - Completed No comment

OQ.2 1 Machine parts - Completed No comment

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 12 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

11- Test Protocols


Each test is specified by a protocol set out on one page in a consistent format:

Header Identify the machine's unique serial and customer


Test reference Unique identification of the test, with version number
Test title The name of the item to be tested
Purpose A brief statement of the aims of the test
The steps to be taken to conduct the test satisfactory including where
Method
appropriate any preparation, and documentation
The condition that must be met for the test to be passed failure to
Acceptance criteria
meet one or more acceptance criteria causes the test to fail
Test results A form for recording of test results
A section for recording any relevant supplementary comments.
Comments
In addition, where appropriate the protocols will include
A section for nothing the reference of any further documents that are
Document reference
needed as supportive evidence –e.g. printout, calibration certificates.
A section for recording the reference identities of any calibrated
Instrumentation identities
measuring instrumentation required.
Confirmation that an authorized "test approver" has formally
Approval signature
approved the test method before being used.
A section for a clear, unambiguous statement (Yes/No) As to whether
Compliance signature the test has been passed to be completed, signed and dated by the
authorized tester
A section for confirmation that the tests have been completed, an
Review signature
authorized "test reviewer" has formally reviewed the results.

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 13 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

12- Operational qualification tests

Test ref. Version No. Test title

OQ.12.01 1 Machine Control Panel


OQ.12.02 1 Machine parts

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 14 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ.12.01 Machine Control Panel

OQ. Test No. 12.01.01 Mixing On Push Button

Test Criterion The machine detects if the Mixing On Push Button is


on to start the mixing operation

Pass/Fail
Expected Result 1  Machine is not running. Pass
2  Tension Pilot Lamp is extinguished Pass

Prerequisites :
Test Procedure Machine ready for production

1  Turn off the main electricity selector

2  Press Mixing On Push Button

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 15 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.01.01Mixing On Push Button

 Switch on Main electricity selector

Remedy  Press Mixing On Push Button to start the mixer

 Tension Pilot Lamp is lighted up

Comment

Name Position Signature Date


Qualification
Done by: Ahmed Bassiouny 29-9-2014
Engineer
Qualification
Reviewed by: Dina Rabea 29-9-2014
Engineer
Approved by:

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 16 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.01.02 Press emergency push button

The Machine detects if the emergency push button on


Test Criterion the control panel is not working.

Pass/Fail
 Machine cannot be started where
1 Pass
Expected Result ever you pressed
 Mixing Stop Pilot Lamp is lighted
2 Pass
up

Prerequisites :
Test Procedure Machine ready for production

1  Press Emergency push button

2  Start machine

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 17 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.01.02 Press Emergency push button

Remedy  Release Emergency push button

 Press Reset push button


 Press Mixing on push button to start the mixer
operation
 Mixing Stop Pilot Lamp is extinguished

Comment

Name Position Signature Date


Qualification
Done by: Ahmed Bassiouny 25-9-2014
Engineer
Qualification
Reviewed by: Dina Rabea 25-9-2014
Engineer
Approved by:

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 18 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.01.03 Auxiliarsys Insertion Selector

Test Criterion The Machine detects if the Auxiliarsys Insertion


Selector is switched on then the mixer control panel is
supplied with electricity

Pass/Fail
Expected Result 1  Machine is not running Pass
2  All control panel items are off Pass

Prerequisites :
Test Procedure Machine ready for production

1  Switch off Auxiliarsys Insertion Selector

2  Press Mixing on push button to start the mixer

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 19 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.01.03 Auxiliarsys Insertion Selector

 Switch on Auxiliarsys Insertion Selector

 Press Reset Push Button


 Press start Mixing on push button to start the
mixer operation

Comment

Name Position Signature Date


Qualification
Done by: Ahmed Bassiouny 25-9-2014
Engineer
Qualification
Reviewed by: Dina Rabea 25-9-2014
Engineer
Approved by:

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 20 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.01.04 Mixing Speed Potentiometer

Test Criterion The Machine detects if Mixing Speed Potentiometer


turned clockwise then the mixer speed will be increased

Pass/Fail
Expected Result
1  Mixer rotation speed increased Pass

 Digital speed indicator display the


2 Pass
increasing of the speed (RPM)

Prerequisites :
Test Procedure Machine ready for production

 Turn Mixing Speed Potentiometer clockwise to


1
increase the mixer speed rotation
 Press Mixing on push button to start the mixer
2
operation

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 21 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.01.04 Mixing Speed Potentiometer

 Adjust Mixing Speed Potentiometer according to


Remedy
the speed requirements for the patch

Comment

Name Position Signature Date


Qualification
Done by: Ahmed Bassiouny 25-9-2014
Engineer
Qualification
Reviewed by: Dina Rabea 25-9-2014
Engineer
Approved by:

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 22 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.01.05 Mixing Timer

The Machine detects if the Mixing Timer set to specific


Test Criterion time in (minutes) then the mixer will be operated until the
mixing timer countdown to (zero)

Pass/Fail
 Mixer is running until the mixing
1 Pass
timer countdown to (zero)
Expected Result
 Mixing End Pilot Lamp will be
2 lighted up when mixer stopped Pass
after the operation ended

Prerequisites :
Test Procedure Machine ready for production

1  Set the mixing timer to 10 (minutes)

2  Press mixing on push button

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 23 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.01.05 Mixing Timer

 Adjust the mixing timer to the specific time for


Remedy the patch according to the requirements

 Press Mixing on push button to start the mixer

Comment

Name Position Signature Date


Qualification
Done by: Ahmed Bassiouny 25-9-2014
Engineer
Qualification
Reviewed by: Dina Rabea 25-9-2014
Engineer
Approved by:

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 24 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

12.02 Machine parts

OQ. Test No. 12.02.01 Vacuum Pump

To ensure that Vacuum Pump has started working


Test Criterion

Pass/Fail

1  The air line is off Pass


Expected Result
 The powder cannot be conveyed to
2 Pass
the mixer tank

Prerequisites :
Test Procedure Machine ready for production

1  Switch off vacuum pump switch

2  Press mixing on push button

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 25 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.02.01 Vacuum Pump

Remedy  Press mixing off push button to stop the mixer

 Switch on vacuum pump switch to start filling the


mixing tank with powder
 Press mixing on push button

Comment

Name Position Signature Date


Qualification
Done by: Ahmed Bassiouny 25-9-2014
Engineer
Qualification
Reviewed by: Dina Rabea 25-9-2014
Engineer
Approved by:

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 26 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.02.02 Butterfly valve

To ensure that the Butterfly valve is working


Test Criterion

Pass/Fail
Expected Result  No powder will be conveyed due
1 to the opening of Butterfly valve Pass
gate
 Some powder will be conveyed
2 and discharged through the Pass
Butterfly valve gate

Prerequisites :
Test Procedure Machine ready for production

1  Open the Butterfly valve gate manually

2  Start the vacuum pump operation

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 27 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.02.02 Butterfly valve

Remedy  Stop the vacuum pump

 Close the Butterfly valve gate


 Switch on the vacuum pump to fill the mixing
tank with powder (Patch)
 Press Mixing on push button to start the mixer

Comment

Name Position Signature Date


Qualification
Done by: Ahmed Bassiouny 25-9-2014
Engineer
Qualification
Reviewed by: Dina Rabea 25-9-2014
Engineer
Approved by:

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 28 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.02.03 Safety Gate Sensor

The machine detects if the safety gate is opened then the


Test Criterion Safety Gate Sensor will send a signal to stop the mixer
immediately

Pass/Fail

1  The mixer is running Pass

Expected Result  The mixer will be stopped


2 immediately at any position when Pass
the safety gate is opened
 Mixing Stop Pilot Lamp is lighted
3 Pass
up

Prerequisites :
Test Procedure Machine ready for production

1  Press Mixing on push button to start the mixer

2  Open the safety gate

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 29 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.02.03 Safety Gate Sensor

Remedy  Close the safety gate

 Press Reset push button

 Press Mixing on push button to start the mixer

Comment

Name Position Signature Date


Qualification
Done by: Ahmed Bassiouny 25-9-2014
Engineer
Qualification
Reviewed by: Dina Rabea 25-9-2014
Engineer
Approved by:

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 30 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.02.04 Mixer Interlock Sensor

The machine detects if the machine is stopped then


Test Criterion the Mixer Interlock Sensor will activate the interlock
system to prevent the mixer rotation for safety

Pass/Fail

1  The mixer is running Pass

Expected Result  Then after press mixing off push


button, the mixer will be rotated by
2 inertia until stopping in vertical Pass
position but can be rotated easily
by the operator hand (manually)

Prerequisites :
Test Procedure Machine ready for production
 Disconnect the Mixer Interlock Sensor from the
1 main electricity panel
2  Press mixing on push button to start the mixer
 Then press Mixing off push button to stop the
3
mixer

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 31 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.02.04 Mixer Interlock Sensor

 Reconnect the Mixer Interlock Sensor


 Press mixing on push button to start the mixer

Comment

Name Position Signature Date


Qualification
Done by: Ahmed Bassiouny 25-9-2014
Engineer
Qualification
Reviewed by: Dina Rabea 25-9-2014
Engineer
Approved by:

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 32 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.02.05 Positioning cam Proximity

Test Criterion The machine detects if the machine is running then


the Positioning cam Proximity will monitor the speed of
running

Pass/Fail
Expected Result
1  The machine running Pass

2  The speed indicator will be read Pass


(0.00 RPM)

Prerequisites :
Test Procedure Machine ready for production
 Disconnect the Positioning cam Proximity from
1 the main electricity panel
2  Press mixing on push button to start the mixer

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 33 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

OQ. Test No. 12.02.05 Positioning cam Proximity

 Reconnect Positioning cam Proximity

Remedy  Press mixing on push button to start the mixer


 Speed indicator will screen the current
rotation speed (RPM)

Comment

Name Position Signature Date


Qualification
Done by: Ahmed Bassiouny 25-9-2014
Engineer
Qualification
Reviewed by: Dina Rabea 25-9-2014
Engineer
Approved by:

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 34 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

13- Job sheets

 The following tables list a series of possible faults which may be encountered
during normal machine operation.

 After resetting any mechanical faults remember to press the RESET pushbutton
and check the list of messages on the machine display.

 The following conditions must be observed in order to resolve the problems


listed below :

 When carrying out operations within the machine ,always remember to exercise
extreme caution as regards the surrounding devices , so as to avoid injury to
persons or damage to the machine

 Always ensure that all of the necessary checks or procedure have been completed

 Wear protective gloves

 Never leave objects ,such as wrenches inside the machine

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 35 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

14- Non-conforming Report

Test reference Test title


Observation

Person present
Name Signature Date

Follow up
Agreed corrective action
Date done backup evidence ref.

Name Position Signature Date


Qualification
Done by: Ahmed Bassiouny 25-9-2014
Engineer
Qualification
Reviewed by: Dina Rabea 25-9-2014
Engineer
Approved by:

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 36 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

15- Summary Report


 All tests are done without any deviation.

Name Position Signature Date

Qualification
Done by: Ahmed Bassiouny 25-9-2014
Engineer
Qualification
Reviewed by: Dina Rabea 25-9-2014
Engineer
Approved by:

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 37 of 38


ROTA 940 PA (A3) MACHINE OPERATION
QUALIFICATION PROTOCOL (OQ)
Al kawthar St., building 6.
PROTOCOL (OQ)
31st km Alex-Cairodesertroad. Customer: PHARCO
Al-Amriya, Alexandria,Egypt.
Protocol no. : A02-OQ041-2014 Pharmaceutical industries Co.
Tel/Fax: +2-03-4499924
Mob. : +20-12-22208383 Date of issue: 1-10-2014 Customer ID: A02
E-mail:Greentk.info@gmail.com

16- Attachments

Attachment No. Description

Name Position Signature Date

Qualification
Done by: Ahmed Bassiouny 25-9-2014
Engineer
Qualification
Reviewed by: Dina Rabea 25-9-2014
Engineer
Approved by:

ROTA 940 PA (A3) MACHINE OPERATION QUALIFICATION PROTOCOL (OQ) Page 38 of 38

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