U R T Foraw R L F: Ser Equirements Emplate Ide Ange Iquid Iller

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USER REQUIREMENTS TEMPLATE

for a WIDE RANGE LIQUID FILLER


Page 1 of 24

USER REQUIREMENTS SPECIFICATION Doc ID: Wide Range Liquid Filler


JETT Wide Range Liquid Filler Rev. 0

August 2005

TABLE OF CONTENTS

1 INTRODUCTION..................................................................................................................................4
2 OVERVIEW.........................................................................................................................................5
3 OPERATIONAL REQUIREMENTS................................................................................................5
3.1 FUNCTIONS................................................................................................................................. 5
3.1.1 Operation...................................................................................................................................5
VIAL SIZE....................................................................................................................................................6
NECK FINISH.............................................................................................................................................6
HEIGHT........................................................................................................................................................6
WIDTH..........................................................................................................................................................6
VIAL ID........................................................................................................................................................6
STOPPER ID................................................................................................................................................6
PLUG/ LYO..................................................................................................................................................6
RATE (V/MIN).............................................................................................................................................6
COMMENTS................................................................................................................................................6
3.1.2 Product Output..........................................................................................................................7
3.1.3 Product Contact Parts...............................................................................................................7
3.1.4 Power Failure and Recovery.....................................................................................................8
3.1.5 Emergency Stop.........................................................................................................................8
3.1.6 Alarms and Warnings................................................................................................................9
3.2 DATA & SECURITY................................................................................................................... 10
3.2.1 Interfaces.................................................................................................................................10
3.2.2 Interface with Supervisors.......................................................................................................11
3.2.3 Interface with Other Systems...................................................................................................11
3.2.4 Interface with Equipment.........................................................................................................12
3.2.5 Data Collection........................................................................................................................12
3.3 ENVIRONMENT.......................................................................................................................... 13
3.3.1 Layout......................................................................................................................................13
3.3.2 Physical Conditions.................................................................................................................13
4 CONSTRAINTS.................................................................................................................................14
4.1 MILESTONES AND TIMELINES.................................................................................................... 14
4.2 COMPATIBILITY........................................................................................................................ 15
4.2.1 PLC Controllers.......................................................................................................................15
4.2.2 Utilities....................................................................................................................................15

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USER REQUIREMENTS SPECIFICATION Doc ID: Wide Range Liquid Filler


JETT Wide Range Liquid Filler Rev. 0

August 2005

4.3 AVAILABILITY.......................................................................................................................... 16
4.4 PROCEDURAL CONSTRAINTS..................................................................................................... 16
4.5 MAINTENANCE.......................................................................................................................... 17
5 LIFE-CYCLE.....................................................................................................................................17
5.1 DEVELOPMENT.......................................................................................................................... 17
5.2 TESTING.................................................................................................................................... 18
5.3 DELIVERY................................................................................................................................. 18
5.3.1 Documentation.........................................................................................................................18
5.4 SUPPORT................................................................................................................................... 19
5.4.1 Start-up Support.......................................................................................................................19
5.4.2 Post Start-up Support..............................................................................................................19
6 GLOSSARY........................................................................................................................................20
7 REFERENCES...................................................................................................................................20
8 APPROVAL........................................................................................................................................20

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USER REQUIREMENTS SPECIFICATION Doc ID: Wide Range Liquid Filler


JETT Wide Range Liquid Filler Rev. 0

August 2005

REVISION HISTORY
Rev. Date Approval Revision Summary
A1 12/21/00 TGP Initial Draft
A2 1/16/01 TGP Incorporated comments from JETT Group and Gary Pardekooper
A2 2/5/01 TGP Incorporated comments from JETT meeting of 1/24/01
A3 3/13/01 TGP Moved notes to second page, modified procedural constraints as
requested from JETT meeting on 2/15/01
B1 7/16/02 TGP Changes from validation review of 1/17/02
C1 04/17/03 MRR Format Review

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USER REQUIREMENTS SPECIFICATION Doc ID: Wide Range Liquid Filler


JETT Wide Range Liquid Filler Rev. 0

August 2005

Project No.: Wide Range Filler #1234

Document No.: 8111234567

Document Description: Wide Range Filler User Requirements Specification

1 INTRODUCTION
This document was generated under the authority of the ___________________ Company for the
purpose of specifying the user requirement for a wide range filler that will fill, sample checkweigh
and stopper a wide range of vial sizes in a pharmaceutical environment. The User Requirements
Specification (URS) is provided to aid the user through the important components, variables and
options necessary to procure a functional filling stoppering system that meets the users needs in the
most cost-effective method possible. The URS is then provided to the Supplier to provide a price
quote for the wide range filler supply including the design and manufacture of the equipment.

This URS will be recognized as an integral part of the procurement agreement with the selected
equipment vendor. The equipment supplier or vendor will abide by the information and conditions
set forth by this document as well as the standard purchasing term and conditions of the
____________________ Company.

The wide range filler will be interfaced to the output of a depyrogenation tunnel, and will be located
in a designated operating area within a cGMP packaging operation.

An equipment validation plan has been developed to outline the planned tasks and expectations for
validation of the wide range filler. This plan has been included as Attachment _____. The
equipment supplier or vendor has specific responsibilities as outlined by the Validation Plan and this
document.

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USER REQUIREMENTS SPECIFICATION Doc ID: Wide Range Liquid Filler


JETT Wide Range Liquid Filler Rev. 0

August 2005

2 OVERVIEW
The wide range liquid filler shall process pharmaceutical vials under sanitary conditions with the
following functions:

 Vial Filling
 Vial Stoppering
 Oxygen Reduction
 Sample Checkweighing
 Vial Eject
 Other (specify):

3 OPERATIONAL REQUIREMENTS
3.1 Functions

3.1.1 Operation

The wide range filler is expected to satisfactorily fill and stopper vials at
production speeds up to and including ______________ vials per minute.
Satisfactory performance is defined by the following criteria:

3.1.1.1 Sterilized vials are to be run through the wide range filler without
becoming contaminated, disoriented, marred, scratched, broken or
otherwise damaged in the process. Properly filled vials are defined as
those possessing the desired dose (+/- _____% by weight) with a
properly seated stopper. Specifically, the rejection rate caused by the
wide range filler must not exceed ______ % during any given
production run.

3.1.1.2 The machine shall not experience more than _____ % downtime at
production speeds up to and including the ______ vials per rate
specified, during an eight hour production run.

3.1.1.3 The vial eject system must be 100% reliable. It must eject all rejected
vials, and not eject acceptable vials.

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USER REQUIREMENTS SPECIFICATION Doc ID: Wide Range Liquid Filler


JETT Wide Range Liquid Filler Rev. 0

August 2005

3.1.1.4 The machine changeover between vial sizes by a single operator is


expected to take no longer than ____ minutes from the last vial out of
the prior run to the first vial out of the next run.

3.1.1.5 Commodity Table


Vial Neck Vial Stopper Plug/ Rate
Height Width Comments
Size Finish ID ID Lyo (V/Min)

3.1.1.6 Vial Handling


The wide range filler shall transfer, fill, checkweigh and stopper
pharmaceutical grade glass or plastic vials at the rates defined in the
commodity table:

The wide range filler shall be operable by one person, with safety
related faults stopping the machine immediately. The machine shall not
be allowed to restart without operator intervention.

3.1.1.7 Vial filling


The wide range filler shall fill vials with
__________________________product that has a specific gravity of
_________________ to an accuracy of +/- __________%. The product
has _______________________________________ foaming
tendencies.

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USER REQUIREMENTS SPECIFICATION Doc ID: Wide Range Liquid Filler


JETT Wide Range Liquid Filler Rev. 0

August 2005

3.1.1.8 Oxygen Reduction


The wide range filler will reduce the levels of oxygen in the headspace
of the vial to __________%, as measured using sparged WFI for a
product. The Oxygen Reduction System must be selectable to allow
flow of nitrogen to the vial only for products that are oxygen sensitive.

3.1.1.9 Stoppering
The wide range filler shall stopper vials with stoppers listed, and at the
rate defined in the commodity table. Silicone treatment of stoppers
being placed is defined as_______________
__________________________________________________________
______________________

3.1.1.10 Checkweighing
The wide range filler shall sample checkweigh vials prior to filling
(tare) and after filling (gross). The weight accuracy shall be +/-
__________% of fill weight. The sampling frequency shall be
__________ weighs/minute.

3.1.1.11 Vial Eject


The wide range filler shall eject all vials that are faulty due to
__________________________________________________________
__________________________________________________________
Vials shall be removable from the filler for manual sampling.

3.1.2 Product Output


The wide range filler shall have a machine efficiency rate of ________ %, as
measured by the actual number of good vials filled and stoppered during a one
hour test run, divided by the calculated number at the rate defined in the vial
commodity table. Machine efficiency rate excludes downtime due to faulty
commodities or supply issues.

3.1.3 Product Contact Parts


All product contact parts shall be constructed from materials acceptable to the
product and sterility assurance methods. Certificates for material, weld and finish
shall be provided.

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USER REQUIREMENTS SPECIFICATION Doc ID: Wide Range Liquid Filler


JETT Wide Range Liquid Filler Rev. 0

August 2005

3.1.4 Power Failure and Recovery


On power failure, the system shall fail into a “safe state.” On power restoration,
the system shall not restart without operator or communication-link input.

All equipment shall be designed to retain the PLC program in case of power loss,
and be able to recover with minimal operator actions.

A “safe state” shall be defined as:


 All motion stopped on the machine
 Reset required before machine can be restarted
 No damage to machine will occur as a result of going to the safe state.

3.1.5 Emergency Stop


Emergency-stop buttons shall be supplied within the reach of the operator at
normal operator stations. When activated, the emergency stop shall shut the
system down immediately in accordance with the following requirements:

No damage to the machine will occur as a result of an emergency stop.

Emergency stop will seal product path or take actions to prevent product
contamination if so equipped.

The machine shall not be allowed to restart without operator intervention. It shall
be necessary to restore the emergency stop button to the original state, and reset the
system before restarting.

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USER REQUIREMENTS SPECIFICATION Doc ID: Wide Range Liquid Filler


JETT Wide Range Liquid Filler Rev. 0

August 2005

3.1.6 Alarms and Warnings


The wide range filler shall be equipped with the following alarms and warnings:

Cycle Operate
Alarm Or Warning Immediate*
Stop** Alert***
PLC Battery Low X

Emergency Stop X

Machine Overtorque X

No Vials X

Stopper Hopper Low X

No Stoppers X

Missing Stoppers X

Low Air Pressure X

High Stoppers X

Output Full X

Checkweigh Low Alarm X

Checkweigh Low Alert X

Checkweigh High Alert X

Checkweigh High Alarm X

* “Immediate alarms” shall take action immediately to stop the wide range filler. The operator
shall be required to acknowledge the alarm before the alarm can be reset and the machine
restarted.

** “Cycle-Stop alarms” shall take action at the end of a fill cycle to stop the wide range filler. The
operator shall be required to acknowledge the alarm before the alarm can be reset and the machine
restarted.

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USER REQUIREMENTS SPECIFICATION Doc ID: Wide Range Liquid Filler


JETT Wide Range Liquid Filler Rev. 0

August 2005

*** “Operator Alert” allows the machine to continue to run, but provides an “alert” message to be
displayed on the operator screen. The operator shall be required to acknowledge the alert in order
to remove the warning message form the operator screen.

3.2 Data & Security

3.2.1 Controls provided with a data collection systems intended for use in the
manufacture of pharmaceutical products shall comply with 21 CFR, Part 11 of the
FDA cGMP regulations or _______________ Company policy and procedure.
The supplier shall stipulate the methods by which this criterion is met.

3.2.2 Interfaces
The Programmable Logic Controller / Operator-Interface Panel system (hereafter
referred to as the “PLC/OIP system”) shall include interfaces with the Operator,
Supervisors, external equipment, and the User’s control system to ensure safe,
reliable, continuous, and automatic operation and easy, safe, and reliable
configuration.

3.2.2.1 Interface with Operators

The PLC/OIP system shall include interfaces with the Operator that ensures
easy, safe, and reliable operation.
An operator-interface panel shall be provided and mounted on the machine.
This panel shall provide the necessary switches, indicators, and devices to
operate the wide range filler. The following shall be displayed:
 Machine Drive Controls
 Vial Transfer Controls
 Filling Controls
 Checkweigh Controls
 Stoppering Controls
 Eject Controls
 Utility Controls
 Alarms and Warnings.
 System Status (e.g., “ready,” “running,” etc.).
 Other (specify).

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USER REQUIREMENTS SPECIFICATION Doc ID: Wide Range Liquid Filler


JETT Wide Range Liquid Filler Rev. 0

August 2005

3.2.3 Interface with Supervisors


The PLC/OIP system shall provide supervisory access to specific functions to
ensure easy, safe, and reliable configuration of the wide range filler. The following
shall be accessible only to Supervisors:
 Fill Volume Adjustment
 Checkweigh Alarm and Alert Settings
 Vial Counter Reset
 Alarm Settings.
 Other (specify).

3.2.4 Interface with Other Systems


Access to all Input/Output values and system status bits by an external computer
system(s) shall be provided through a data-communication link to the PLC and/or
PLC/OIP. Security for data and operator access is provided by ______________.

List the application that provides security functions to the system, either internal
via the local OIP or external via a SCADA system, etc.
The PLC/OIP system shall include interfaces with the User’s control system to
facilitate recipe download and configuration.

The port shall be configured to communicate the following data to a supervisory


control and data acquisition (SCADA) node (Note: the SCADA system shall be
supplied and installed by the User):
 Machine Rate
 Vial Count
 Checkweigh Data
 Alarms and Warnings.
 System Status (e.g. “off,” “ on,” “standby” states, etc.).
 Other (specify).

3.2.5 Interface with Equipment


The PLC/OIP system may include interfaces with external equipment to ensure
safe, continuous transfer of vials without operator intervention.

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USER REQUIREMENTS SPECIFICATION Doc ID: Wide Range Liquid Filler


JETT Wide Range Liquid Filler Rev. 0

August 2005

3.2.6 Data Collection

3.2.6.1 Data required for collection


 Machine Rate
 Vial Count
 Checkweigh Data
 Alarms and Warnings.
 System Status (e.g. “off,” “ on,” “standby” states, etc.).
 Other (specify).

3.2.6.2 Data Collection and Storage Requirements


 None

3.3 Environment

3.3.1 Layout
Allocated floor space for the wide range filler is _______ inches wide by ________
inches deep with a 24 inch corridor around the periphery of the machine.

Vertical clearance is _________ inches.

See attached drawing #________________________ (if applicable).

3.3.2 Physical Conditions


The wide range filler shall be mounted in an environment with a temperature range
of ______ to ______ °Fahrenheit and non-condensing humidity.

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USER REQUIREMENTS SPECIFICATION Doc ID: Wide Range Liquid Filler


JETT Wide Range Liquid Filler Rev. 0

August 2005

Vibration levels are:


Negligible.
Other (specify).

Electromagnetic interference levels are:


Negligible.
Other (specify).

This area is intended for the following use:


Class 100 Cleanroom.
Other (specify).

4 CONSTRAINTS
4.1 Milestones and Timelines
The Supplier shall provide a written proposal within _______ weeks of receipt of this
document at the Supplier’s local office.

The Supplier shall provide a Functional and Design Specifications within ________ weeks
of receipt of the purchase order.

The User shall review, comment and/or approve, and return the Functional and Design
Specification to the Supplier within _______ weeks of receipt from the Supplier.

The Supplier shall provide the Factory Acceptance Test Specification within _______
weeks of receipt of approved the Functional and Design Specification. The User shall
review, comment and/or approve, and return the test specifications to the Supplier within
_______ weeks of receipt from the Supplier.

The wide range filler shall be delivered to the User’s receiving dock on or before
_________________.

The Preferred Format Is:

Date written proposal/quote required:


Date purchase order will be placed by:
Functional and Design Specification delivery date:
Factory Acceptance Test Plan due for review:
Factory Acceptance Test Plan due for approval:

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USER REQUIREMENTS SPECIFICATION Doc ID: Wide Range Liquid Filler


JETT Wide Range Liquid Filler Rev. 0

August 2005

Date equipment is required on-site:

4.2 Compatibility

4.2.1 PLC Controllers


The Supplier shall utilize manufactured programmable logic
controllers that shall include a ___________________ communications port. The
Supplier shall provide documentation that the program (embedded software) was
developed and coded utilizing _______ program development and
documentation software.

The Supplier shall identify the impact of adhering to the attached Preferred
Manufacturers List.

4.2.2 Product Contact Parts


All product contact parts shall be constructed from materials acceptable to the
product and sterility assurance methods. Certificates for material, weld and finish
shall be provided.

4.2.3 Utilities
The User shall ensure that the following utilities are available and that the utility
supply lines and piping are terminated with fittings or connections, which are
compatible with those described on the Customer Connection Drawing.

The Supplier shall specify utility data, which is marked with an asterisk (“*”).

Utility requirements, which are not specified or marked with an asterisk, shall be
brought to the attention of the User. These requirements shall be approved by both
the User and the Supplier before system design begins.

4.2.3.1 “Primary” Conditions


Primary Electrical Service: _______ VAC, _______ amps, _______ ph, ______ Hz
Secondary Electrical Service: _______ VAC, _______ amps, _______ ph, ______ Hz

Instrument Air: _______ cfm @ _______ ± _____ psig (minimum: 2 cfm @ 80 psig).

Clean, Filtered Air: _______ cfm @ _______ ± _____ psig (minimum: .5 cfm @ 80 psig).

Nitrogen: _______ cfm @ _______ ± _____ psig (Minimum: 3 cfm @ 25 psig).

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USER REQUIREMENTS SPECIFICATION Doc ID: Wide Range Liquid Filler


JETT Wide Range Liquid Filler Rev. 0

August 2005

SIP Steam: _______ C @ ________ ± _____ psig (Minimum: 135C @ 30


psig).

4.3 Availability
The Wide Range Filler is intended to be operated:

Continuously
Regularly
_________ hours per day.
_________ hours per week.
Other (specify).

_________________________________________________________________________
_________________________________________________________________________

Operation of the wide range filler shall be shut down, and the machine shall be available
for maintenance or service:
_______ hours per week.
_______ continuous hours per week.
_______ days per month.
_______ weeks per year.

4.4 Procedural Constraints


The wide range shall be designed to meet the appropriate GMP regulations. e.g.: cGMP 21 CFR
part 210 and 211 as published at the time of order.

Controls for the wide range filler shall meet the appropriate electrical requirements. e.g.:
NFPA/NEC 70 and 79 for industrial machinery.

Control panels for the wide range filler shall meet the appropriate certifications. e.g.: Underwriters
Laboratories UL-508A certification for industrial equipment.

The wide range filler shall meet the appropriate safety regulations. e.g.: OSHA regulations for the
safety of operators of equipment with regards to safety, guarding and noise.

The wide range filler shall meet CE requirements if delivered to the European Community.

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JETT Wide Range Liquid Filler Rev. 0

August 2005

All piping welds shall meet the appropriate piping regulations. e.g.: ASME and 3A specification
requirements.

Other standards are attached. The Supplier shall adhere to the indicated sections only.
Installation, operation, and maintenance instruction documentation for the system shall be
developed to a level that is comprehensible by a high school graduate.

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JETT Wide Range Liquid Filler Rev. 0

August 2005

4.5 Maintenance

4.5.1 The vial washer shall be maintained on a schedule as indicated by the supplier. Supplier is to
provide (at minimum) the following maintenance instructions.

4.5.1.1 Maintenance activities for all sub-systems (maintenance and operation manuals of vendor
equipment).

4.5.1.2 A comprehensive lubrication list and recommended lubrication schedule.

4.5.1.3 A comprehensive recommended maintenance (regular recommended inspection intervals, wear


points, recommended spare parts list)

4.5.1.4 Supplier shall supply ________ copies of operation, installation, maintenance and de-
commissioning manuals.

5 LIFE-CYCLE
5.1 Development

The Supplier shall provide a Quality and Project Plan as part of its proposal. The Supplier shall
have a quality system in place. Internal quality procedures shall be available for the User’s review.

The Supplier shall provide a Project Manager for the project to provide a single communication
point with the User.

The project shall utilize the GAMP methodology when developing the system and documentation.

5.2 Testing
In order to verify machine performance, the User shall witness the execution of the approved
Factory Acceptance Test procedures. The Supplier shall notify the User _______ weeks in advance
of the start of this test.

5.3 Delivery
The wide range filler, with all options, equipment, and the documentation listed below, shall be
delivered to the User’s receiving dock.

5.3.1 Documentation

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August 2005

The Supplier shall use the formats described in the current version of the GAMP Supplier Guide to
produce the documentation. The Supplier shall provide the documentation for preliminary review.
The Supplier shall provide documentation reflecting “as-built” condition with final delivery.

All final documents shall be shipped with transmittals that identify them as contractually required
documents. All final documents and drawings shall reflect “as-built” condition.

All documents shall be in the language of the destination country, and supplied with hard copies
and electronic versions supplied in the format identified for each document:

 Project Plan
 User Requirements Specification
 Functional Specification
 Design Specification
 Software Module Test
 Software Integration Test
 Controls Test
 Hardware Installation Test
 Operational Test
 Factory Acceptance Test
 Operator, Maintenance and Service Manuals
 Process and Instrumentation Diagram (P&ID)
 Instrument Listing
 Control Schematics
 Control Panel Assembly Drawings
 Machine Assembly Drawings
 Bill of Materials
 Spare Parts List
 Component Cut Sheets
 PLC Program Printout and Disk File

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 OIP Configuration Printout and Disk File

5.4 Support

5.4.1 Start-up Support

5.4.1.1 Start-up support shall consist of ______ weeks of full time assistance on the User’s site for
rigging, installation, start-up and commissioning.

5.4.2 Training

5.4.2.1 User training shall consist of ______ hours of Operator training and _______ hours of
Maintenance training.

5.4.3 Post Start-up Support

5.4.3.1 Post start-up support shall consist of monthly User site visits for a period of _____ years after the
completion of commissioning activities.

5.4.4 Technical Support

5.4.4.1 Technical support shall be provided via telephone for a period of _____ years following the
completion of commissioning.

5.4.4.2 A recommended replacement parts list including normal lead times shall be provided for the
machine and all sub-assemblies.

5.4.5 User Site Support

5.4.5.1 The Supplier shall notify the User of preventative maintenance system improvement availability.

6 GLOSSARY
Table 6.0 Glossary
Acronym Definition
C Degrees Celsius

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August 2005

BL Biohazard Level
CFR Code of Federal Regulations
DB Decibels
EMI Electro-Magnetic Interference
M Meter
GUI Graphic User Interface
HMI Human – Machine Interface
HVAC Heating, Ventilation, and Air Conditioning
ISO International Organization for Standardization
JETT Joint Equipment Transition Team
LEL Lower Explosion Limit
OIP Operator Interface Panel
RFI Radio Frequency Interference
URS User Requirement Specification

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7 REFERENCES
Table 7.0 References
Document Attached to URS (Yes / No)
Equipment Validation Plan
Current revision of GAMP Guidelines
Vendor Piping Certification (if applicable)
Customer Connection Diagram
Approved Instrumentation List
Process Flow Diagram
21 CFR Part 11
National Electric Code

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8 APPROVAL
This document has been reviewed by the User Project Manager and approved for
use by the Supplier.

Printed/Typed Name Signature Date

This document has been reviewed by the User Quality Assurance Group and
approved for use by the Supplier.

Printed/Typed Name Signature Date

This document has been reviewed by the Supplier Project Manager and approved
for use by the Supplier Project Team.

Printed/Typed Name Signature Date

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