| Costas
B. Chantzis, pharmaceutical, medical device, biotechnology, life science,
healthcare, industrial goods markets consultant, expert.
He
has had an impressive and verifiable list of industrial accomplishments
for 27 years in validation, regulatory compliance,
process/system improvement and remediation, regulatory compliance audits, remediation plans development and implementation,
templates for and development, execution, data analysis, and final report
development of ES/COMM./IQ/OQ/PQ/PkV protocols for facilities/utilities,
equipment, and computer systems (GxP and 21 CFR Part 11 regulations), process
analytical technology, quality by design, quality function deployment, design
controls, system/component impact assessment, critical process parameters,
critical quality attributes, deviation investigation, corrective action and
preventative action (CAPAs), quality risk assessment, quality risk
management, PMA, 510K and IDE, modeling, statistics, Six Sigma and Baldrige
performance, lean manufacturing quality and productivity, models/templates for due diligence of regulatory
compliance and operational excellence comprising systems of quality, facility
and equipment, materials, production, packaging and labeling, laboratory
controls as well as intellectual property, product’s commercialization
phases, cost of quality, performance and productivity, manufacturing plants,
and business entities, biomaterials, material surface treatment, tribology,
colloids, cutting tools, membranes, powders, gels, fluid pumping and processing,
aseptic filling, lyophilization, sterilization and packaging, development and revision of standard operational procedures (SOPs) and
Validation Master Plans with an impressive and verifiable list of
accomplishments in pharmaceuticals, medical devices, biotechnology, life
science, healthcare and other industrial sector
projects.
Feel free to download our company's brochure.
Summary:
–Expert
in regulatory compliance audits, remediation plans development and implementation,
templates for and development, execution, data analysis, and final report
development of ES/COMM./IQ/OQ/PQ/PkV protocols for facilities/utilities,
equipment, and computer systems (GxP and 21 CFR Part 11 regulations)
–Experienced
in development and revision of standard operational procedures (SOPs) and
Validation Master Plans
–Have
leading edge knowledge in biomaterials, material surface treatment, tribology,
colloids, cutting tools, membranes, powders, gels, fluid pumping and processing,
aseptic filling, lyophilization, sterilization and packaging
–Have
developed proprietary models/templates for due diligence of regulatory
compliance and operational excellence comprising systems of quality, facility
and equipment, materials, production, packaging and labeling, laboratory
controls as well as intellectual property, product’s commercialization
phases, cost of quality, performance and productivity, manufacturing plants,
and business entities
–Have
thorough know-how in process
analytical technology, quality by design, quality function deployment, design
controls, system/component impact assessment, critical process parameters,
critical quality attributes, deviation investigation, corrective action and
preventative action (CAPAs), quality risk assessment, quality risk management, PMA, 510K and IDE, modeling, statistics, Six Sigma and Baldrige
performance, lean manufacturing quality and productivity tools
–Have
completed successfully numerous regulatory compliance projects for Abbott
Laboratories, Becton Dickinson, Eli Lilly, Purdue Fredricks Laboratories, B. Braun, Schering
Plough and many smaller size companies
Details:
Led the packaging
validation group of medium size NJ pharmaceutical company comprising three
equipment validation engineers for the validation of packaging processes
for over 200 current and new liquid, ointment, cream, aerosol and tablet
pharmaceutical products.
-
Ensured all consent decree, cGMP Workplan
commitments and regulatory compliance initiatives were completed ahead
of time and in full compliance with company standards. Completed commitments
on time for compliance audit responses and preventative actions on protocol
variances.
-
Supervised group towards the completion
of over 150 equipment qualifications and packaging validations in support
of the Validation Certification Program (VCP), New and Base Business Product
Presentations.
-
Drove Continuous Quality Improvement
as a mindset. Reduced equipment qualification protocol variance occurrence
rate to 13%. Achieved 75% first
pass regulatory compliance approval rate for protocol variance reports.
Led consulting
teams and completed GAP analysis, remediation plans implementation, IQ/OQ/PQ
protocol generation, execution, data analysis, and final report preparation
projects for facilities/utilities, equipment, and computer systems (GxP
and 21 CFR Part 11 regulations.)
-
Audited existing validation reports
and developed Periodic Quality Evaluation documents for lyophilization,
autoclaving, washing, depyrogenating, aseptic liquid filling and packaging,
air handling/conditioning (including environmental monitoring), laminar
hood, tank, clean-in-place (CIP), sterilize-in-place (SIP) and sterile
water treatment processes of a Fortune 50 pharmaceutical company.
-
Developed and executed IQ, OQ, PQ and
PV protocols/reports for the validation of analytical laboratory instruments,
liquid, cream and tablet packaging equipment for contract packaging and
drug manufacturing companies.
-
Completed documentation and product
quality audits about the state of control of about 100 manufacturing equipment
and processes for over 3,000 products at 1,000 employee healthcare manufacturing
facility. Assembled documented
evidence that supported the continued use of manufacturing equipment and
processes until validation activities were completed. Documentation
audit comprised the assessment and remediation of over 2,000 SOPs. Product
quality audit comprised the assessment of quality control, nonconformance,
process yield and product incident report (complaint) data for the last
12 months. Established template
for and completed 40 calibration SOPs. Established
template for correctly determining the criticality of over 3,000 medical
products and reclassified their performance characteristics. Established
template for and completed the development of 35 analytical, material and
product test methods.
-
Brought medical device manufacturer
into FDA compliance, reduced by 35% all required documents for manufacture,
management and control of the related products and, significantly improved
the quality of collected data.
-
Assisted major diagnostic kits manufacturer
with $3.1 billion in annual sales to complete re-validation of numerous
marketed products that did not meet minimal FDA requirements. Activities
included design controls, risk assessment, remediation, product and process
characterization, protocols for and review of test method and process validation;
equipment installation and operational qualification. Manufacturing
processes involved various solutions, mixing, lyophilization cycle, filtration,
pumping and aseptic filling, process hold time and sonic welding operations
for hepatitis, retrovirus, cardiovascular disease, cancer, thyroid disorders,
fertility, drug monitoring, congenital and respiratory related test products.
-
Researched, developed and improved the
performance of blood collection test tubes, needles, syringes, blades,
lancets, catheters, drains, hemostats, wound healing and closure agents,
sterile solutions, drapes, gloves, towels, bacterial filters and associated
manufacturing processes; Transferred technology, validated, troubleshot
and improved the performance of manufacturing processes in plants throughout
the US, Mexico, Puerto Rico and England.
-
Improved by 32% sharpness of needle
for blood gas syringe at manufacturing plant of a sister division. Validated
process resulted in timely launch of "Precision Glide" worldwide advertising
campaign and turned around politically explosive situation.
-
Improved by 35% dissolution of lyophilized
heparin powder for blood gas syringe. Optimized
granule particle size, binders, concentration and freeze-drying parameters. Validated
process resulted in timely launch of new product, a $10 million market
opportunity.
-
Improved by 50% quality of blood collection
tubes with computer model predicting performance. Established
and controlled silica powder’s particle size distribution and agglomeration,
the most important process parameter. Validated
process resulted in $2 million annual savings.
-
Identified and satisfied unmet needs
of customer by inventing and completing quantitative competitive evaluation
of suction catheters and suction canister membranes. Solved
airflow restriction and sealing problems, which reversed $500 thousand
product back orders. New advertising
campaign resulted in $5 million sales gain.
-
Reduced tubing and adapter costs of
molded suction catheter by $175 thousand annually. Validated
processes eliminated seventeen-year-old extrusion and molding problems.
-
Developed new package and product performance
profile for haemostatic implant agent. Projected
annual savings, $1.5 million with FDA efficacy test costs reduced by $225
thousand.
-
Qualified and validated PVC suction
catheter kits for radiation sterilization. Evaluation
schedule compressed from twelve months to six. Resulted
in $125 thousand annual savings.
-
Qualified and validated new bottom web
for sterile solution tray with high volume form/fill/seal packaging equipment. Help
redesign and build packaging dies in three months.
Speaking
Engagements:
-
Chairman
of 3.5 hours Regulatory Compliance and Business Excellence Workshop: Regulatory
Compliance and Business Excellence Lessons Learned (Seminar Speaker); Case
Studies on How-To Troubleshoot Quickly and Correctly Your Material and/or
Process Problems With Analytical Laboratory Expertise/Know-How; Data-Driven
Methods for Regulatory Compliance and Business Excellence; Case Study -
Improving Manufacturing Performance & Cycle Time at DuPont Pharmaceuticals,
Interphex 2007 - April 26, 2007, New York, NY
-
Seminar Presenter: Developed and presented
3 hour workshop with subject “Lean Six Sigma for Pharma Manufacturing:
Benefits of Compliance” with only 4 hours prior notice and was congratulated
by the seminar attendees and Conference Director, July 24 - 26, 2006, Philadelphia,
PA
-
Conference Chairman: GMP Requirements,
Outsourcing and Manufacturing of Active Pharmaceutical Ingredients. Presented
seminar on Technology Transfer Strategies, 26-27 March 2001, New Orleans,
LA
-
Conference Chairman: R&D Alliances
for Pharmaceutical/Biotechnology: Build Collaborations and Consortiums
to Achieve Maximum Commercialization. Presented
seminar on Valuation, Contracting and Licensing Agreements, Strategies
for Newly Developed Technologies, 23-24 October 2000, Boston, MA
-
Seminar Presenter: Manufacturing Active
Pharmaceutical Ingredients (APIs): Effective sourcing and supply chain
management of APIs. Cleaning
validation for API manufacturing facilities. Critical
strategies for API regulatory requirements, validation, outsourcing and
technology transfer. Presented
seminar on technology transfer strategies, 6-7 December 1999, Atlanta,
GA
-
Conference Chairman: Biotechnology and
Pharmaceutical Conference: Patents, Licensing, Trademarks and Intellectual
Property ’99: Strategies to maximize protection and financial profits. Presented
seminar on Intellectual Property Valuation, 28-30 July 1999, San Francisco,
CA
-
Seminar Presenter: Business Transformation
Through Re-engineering and Continuous Improvement - powerful models and
practical strategies for an ever rapidly changing global business environment,
19 May 1999, Princeton, NJ
Barry Graziano, pharmaceutical,
medical device, biotechnology, life science, healthcare, industrial goods
markets consultant, expert.
He
has had an impressive and verifiable list of industrial accomplishments
for 35 years in
regulatory compliance, quality risk
assessment, quality risk management, fda, internal and external audits,
process analytical technology (PAT), Drug/Device quality assurance and regulatory affairs:
New product validation and design/transfer including design reviews. Experience
leading global quality system software implementation/ validation projects.
Extensive FDA/ISO/QSR training, auditing (developed internal and external
audit programs) and procedure development. Twenty years experience with
customer complaint investigation and resolutions that yielded increased
market share. Expert in applying Quality Improvement Principles such as
Corrective Action and Preventative Action (CAPA) to a large variety of
processes, primarily chemical based, also includes biological, woven /
non-woven textiles, stainless steel devices, tablet, capsule, Large Volume
Parentals (LVP's), Small Volume Parentals (SVP's), rubber, glass and plastics.
Responsible for QA and validation of class 100 environments, Ethylene oxide,
Cobalt 60 sterilization processes. Provided strategic leadership for re-engineering
and quality improvement that yielded significant competitive advantage.
Proven cost cutter, systematic problem preventer, and inspirational people
developer/educator.
Summary:
Barry
Graziano, is Director of Quality Assurance, Quality Management and Quality
Systems for TechnoBusiness Solutions. Barry has 35
years experience in Drug/Device quality assurance and regulatory affairs:
New product validation and design/transfer including design reviews. Experience
leading global quality system software implementation/ validation projects.
Extensive FDA/ISO/QSR training, auditing (developed internal and external
audit programs) and procedure development. Twenty years experience with
customer complaint investigation and resolutions that yielded increased
market share. Expert in applying Quality Improvement Principles such as
Corrective Action and Preventative Action (CAPA) to a large variety of
processes, primarily chemical based, also includes biological, woven /
non-woven textiles, stainless steel devices, tablet, capsule, Large Volume
Parentals (LVP's), Small Volume Parentals (SVP's), rubber, glass and plastics.
Responsible for QA and validation of class 100 environments, Ethylene oxide,
Cobalt 60 sterilization processes. Provided strategic leadership for re-engineering
and quality improvement that yielded significant competitive advantage.
Proven cost cutter, systematic problem preventer, and inspirational people
developer/educator.
Details:
-
Developed and implemented Documentum
based Global Quality Standards Electronic Document Management System and
website in 6 months. Lead the development teams for 12 Facility and Equipment
Global Standards and 35 Quality System Global Standards. Exceeded all historical
expectations for development and approval of these standards. Implemented
Web-based global training program using WEBEX and INTERCALL that saved
$500M in travel costs.
-
Development and implemented a global
Quality Document Management System. Including development and rollout 130
global, Quality Standards to pharma and device plants worldwide. Developed/led
training workshops for site responsible individuals. Lead standards development
team. Developed Standards Rollout Website and online assessment and implementation
tracking tool. Developed matrix to ensure New Quality Standards fully comply
with CFR 210 and 211, 220, EC and ICH guidelines and regulations. Implementation
completed on time.
-
Developed and implemented an internal
audit program for World Wide Medical Affairs (WWMA) Clinical Development
Program. Lead corrective action for the Audit of the Drug Safety department
that reduced late Serious Adverse Event Reporting from 70% to zero late
in 3 months. Developed and implemented CMOM mission vision and values workshop
to create esprit de corps for newly created department. Implemented WWMA
Global glossary on Lotus Notes. Created CMOM Lotus Notes Workspace for
intradepartmental communication. Directed development and implementation
30 Global Standard Operating Procedures for WWMA.
-
Led implementation of Global Document
Management System using Documentum. Develop new strategy for internal audit
system that changed focus from static compliance to Improving ROI. Developed
new Quality System Workshop and Global Quality Council Strategy.
-
Developed a strategy to transform the
Quality Information System and obtained capital-funding approval of $5MM
for this project. Selected and led a multi-plant team that developed and
implemented an enterprise wide Laboratory Information Management System
(LIMS). This is largest systems project in ETHICON’s Quality Assurance
history. Cost reduction of $1.2MM, Quality System consistency, increased
compliance, transcription error reduction. Validated, nationwide, integrated
quality database, which provided key tool for strategy to foster organizational
transformation from assessment to prevention mode of operation.
-
Chaired Needle Standards Committee,
a team chartered to reengineer Needle Quality System. Developed and implemented
revision to corporate defect classification policy that significantly reduced
liability to 483 observations and recalls. Needle Quality System revisions
and training program saved $1MM in rejects in 1995. Awarded Vice President’s
Award for Teamwork in 1995 for this successful effort.
-
Provided QAE support to team that validated
and implemented the change of Ethylene Oxide Sterilization from 12/88 EO/Freon
to Oxyfume in six months. This team won the Vice President’s Award in 1995.
Supervised
team that developed operator certification program that reduced QA headcount
by 40% while maintaining quality metrics and compliance.
-
Provided in-process inspection, finished
goods inspection/disposition, GMP Audits, quality engineering to the Somerville
needle making, Suture Assembly and Sterilization processes (Co60 and ETO).
Initiated
a Quality Improvement Process using employee empowerment that reduced by
70% and 60% the finished goods failure rate and process deviation, respectively.
Facility recognized as best in Quality Improvement Process in 1991.
-
Initiated Good Manufacturing Practices
(GMP) Committee to develop and implement GMP education program for the
1200 associate plant work force. Reduced Corporate Regulatory audit observations
by 80%. Ethylene Oxide Sterilization audit of July 1991 was the first ever
to receive zero observations.
-
Pioneered ETHICON’s Quality Career Development
Program in 1989. This program refocused associates to other jobs; resulting
in a H/C reduction from 90 in 1989 to 40 in 1993, without a layoff.
-
Established a validation committee and
teams in 1989. Completed validation of all critical processes within 2
years in response to new FDA requirement. Only facility that achieve
our targeted goals.
-
Led plant QA team in program that achieved
ISO 9000 certification in 1994.
-
Directed the Quality Assurance Program
for Becton Dickinson’s transnational, sterile-pre-filled syringe business.
Technologies included: Ethylene Oxide and Cobalt 60 sterilization, glass
forming, stainless steel and rubber processing. Responsible for domestic
and international regulatory affairs.
-
Trained, audited and assured cGMP in
three production facilities located in the US, France and Mexico. Worldwide
sales $60MM.
-
Developed Quality Systems, process validation
protocols and related training programs for transfer of syringe manufacturing
from US to Mexico.
-
Developed and implemented process/facility
validation program for new Ethylene Oxide facility in 1987.
-
Revised and streamlined complaint analysis
and documentation system.
-
Hired to revitalize the quality program
of a division that had over $100MM yearly sales, four plants (US &
UK) and produced over two billion units per year of high volume glass,
plastic and rubber disposable blood collection devices as a strategy to
counter a Japanese entry into B-D’s market that had taken 40% of market
share from B-D in 5 years. Provided QAE support to a quality improvement
program that help regain all lost market share and increase it 10% over
pre-threat level in four years.
-
Directed the design of new facility
for startup in vitro diagnostic reagents, H/W & sterile plastics
(IVD) facility. Vendor program saved $300K in costs.
Speaking
Engagements:
-
ASQ
Quality Conference led session on PAT in Pfizer 2005. Lead American Society
for Quality, Seminar on Computer System Validation in 2003, 2002,
2001, 2000 and 1999.
-
Developed
and hosted American Society for Quality, Seminar on Computer System Validation,
Jan. 22, 1998, Radisson Htl, Seacaucus, NJ. Presented session on, Model
Life Cycle for Software Validation.
-
Chaired
and organized ASQ’s Metropolitan Section 53rd Annual Deming Conference,
Practical
Applications of Deming’s Philosophy. December 8-10, 1997. Resorts
Hotel, Atlantic City, NJ.
-
Chaired
and organized ASQ’s Metropolitan Section 52nd Annual Deming Conference,
Deming’s
System of Profound Knowledge. December 9-11, 1996. Resorts
Hotel, Atlantic City, NJ.
-
Chaired
and organized Seminar on Leadership and Quality Improvement, February 7,
1995, Fordham University, NYC. Presented
session on Leadership and Human Emotion.
John Donohue, pharmaceutical,
medical device, biotechnology, life science, healthcare, industrial goods
markets consultant, expert.
He
has had an impressive and verifiable list of industrial accomplishments
for 29 years in Analytical Laboratory Test Services for Regulatory Compliance
projects. His regulatory compliance record includes:
Summary:
John
Donohue is Director of Laboratory Test Services for TechnoBusiness Solutions. He
is well known in the medical device industry since 1978. He has developed
several successful methods for predicting the shelf life of products such
as the failure or breakage of polymeric delivery systems, the chemical
and physical effects of sterilization and radiation, and the dramatic entry
of Metallocene Polymers into industry. John
has had numerous publications in MDDI magazine, Medical Plastics and Biomaterials
magazine, and has been a regular speaker at the ANTEC, Worldwide Metallocene
Conference, and the Specialty Polyolefins Conference. One of John's unique
abilities is the combined and synergistic use of analytical instrumentation,
chemistry, and knowledge of industrial practice to solve material and/or processing
problems that disrupt product development and/or production. His favorite
machine is a FTIR Microscope and can literally do wonders with it by using
it as a powerful secret weapon to uncover root causes to complex industrial
material, manufacturing and product problems.
Details:
-
Purchased,
operated, and interpreted Analytical Research Lab data including a Nicolet
FTIR Microscope with Micro ATR objective and Mettler Hotstage, Perkin-Elmer
GC/MS, and a SIS Thermal Desorber (ThDsb) for GC/MS sample introduction.
Developed numerous analytical methods using such lab instruments to quantitate
and characterize the application of drugs and other active surfaces to
drug-eluting stents, catheters, and other implantable medical devices for
preventing restenosis, pain, infection, excessive friction. Completed various
cardiology catheter extrusion and material science/spectroscopic characterization
studies for catheters and respiratory devices.
-
Installed,
operated, interpreted, and maintained Analytical Research Lab including:
a Shimadzu GC/MS with a Direct Insertion Probe, a SIS ThDsb, a Hewlett-Packard
GC with an FTIR Detector, and a Nicolet FTIR Microscope with Micro ATR
and Mettler Hotstage. Sherwood's expert in polymer, elastomer, and biomaterial
processing, technology, chemistry, physics, characterization, analysis,
and additives. Developed numerous methods of ThDsb/GC/MS and ThDsb/GC/IR
analyses to identify and quantitate coatings, drugs, contaminants, "blooming"
and additives in and on medical devices, and contaminants, vent clogs,
plate out, and causes of corrosion on injection molds and other processing
equipment. Troubleshot various processes to eliminate "blooming", vent
clogs, plate out, corrosion contaminants. Developed numerous methods using
Nicolet software and Micro ATR FTIR for "instant analyses on contact" of
many devices for quantifying radiation dose, plasticizer content, formulation,
durometer.
-
Part of team that ended voluntary recall
of extremely successful bioresorbable implant, AngioSeal arterial puncture
closure device. Designed polarized microscopy videotaping analytical method
that identified the molding defect causing spurious low break force failures.
Correction of this defect ended recall and maintained critical production
launch. Eliminated bubble formation during AngioSeal molding, preventing
a recall and maintaining critical production launch. Prevented shutdown
of $100 MM/yr. syringe factory by rapid solution of resin problem and development
of FTIR method and software for statistical incoming inspection of pellets
by factory labs.
-
Part of team that implemented new material
for Genius Tympanic thermometer that could withstand cleaning chemicals
without cracking, improving quality/saving millions of dollars in replacement
costs. Worked on numerous implantable, bioresorbable and biostable coated/drug
coated devices.
-
Consulted
start-up company on all technical issues involved in startup of new plastic
medical devices product including design, mold acquisition, production
cost analyses, raw material selection and prototyping.
-
Managed
Analytical Research Lab including a Hewlett-Packard 5890 Series II GC with
a Thermo Nicolet Infrared Detector and software, and a Thermo Nicolet FTIR
Microscope with ATR objective and Mettler Hotstage. B-D's expert in polymers,
additives, formulation, deformulation, and competitive analysis. Team participant
in first release of E Beam and Gamma sterilized syringes in the USA. Wrote
all the Engineering Change Orders and implemented all these new high melt
flow polymers. This increased productivity 14%, saving millions of dollars
per year, and dramatically decreased the number of injection molds required
for production. Patented radiation stable polyolefin formulation.
-
Completed
a number of projects at DuPont’s Potomac River Works Development Laboratory
in Martinsburg, WV that involved polysaccharide hydration, crosslinking,
thermal stability, and shelf life.
Publications/Speaking Engagements:
-
“Predicting
Shelf Life from Accelerated Aging Data: The Variable Q10 and D&A Techniques”
in
MD&DI magazine; June, 1998; J. Donohue,
S. Apostolou.
-
Medical
Design and Manufacturing Conference Proceedings; Anaheim, CA; February,
1997; “How to Predict Shelf Life from Accelerated Data”, J. Donohue.
-
METCON
’96; Worldwide Metallocene Conference; Houston, TX; June, 1996; “Syndiotactic
Polypropylene: Stability to Gamma Radiation”, J. Donohue.
-
ANTEC
’96; The Annual Technical Conference of the SPE; Indianapolis, IN; May,
1996; “The Donohue and Apostolou Process: Predicting Post-Rad Shelf Life
from Accelerated Aging Data”; J. Donohue,
S. Apostolou.
-
SPO
’95; Business Forum on Specialty Polyolefins; Houston, TX; September, 1995;
“Syndiotactic Polypropylene: Radiation-Induced Oxidative Degradation”,
J. Donohue.
-
“Metallocene
Catalysts: Driving the Polyolefin Revolution”; in Medical Plastics and
Biomaterials magazine; Fall, 1994, J. Donohue.
-
ANTEC
’94; San Francisco, CA; May, 1994; “Thermal Decomposition of Bis-Toluidene
Sorbitol into Benzoates during the Molding of Polypropylene”, J. Donohue.
-
SPO
’93; Houston, TX; September, 1993; “The Fire Within: Post-Irradiative Degradation
of Polypropylene”; J. Donohue,
S. Apostolou.
-
ANTEC
’91; Montreal, Quebec; May, 1991; “Radiation Initiated Oxidation of HALS
Stabilized Polypropylene”, J. Donohue.
-
ANTEC
’90; Dallas, TX; May, 1990; “Radiation Effects on Polymers and Hindered
Amine Light Stabilizers”, J. Donohue.
-
“Free-Radical
Degradation and Protection in Irradiated Plastic”; in MD&DI magazine;
April, 1990, J. Donohue.
-
“Shelf-Life
Prediction for Radiation-Sterilized Plastic Devices”; in MD&DI magazine;
January, 1990; J. Donohue,
S. Apostolou.
-
United
States Patent No. 4,710,524; Granted December 1, 1987; “High Energy Radiation
Stabilization of Semi-Crystalline Polymers”; Inventor, John Donohue; Assigned
to Becton Dickinson.
William J. Scherder, pharmaceutical,
vaccine processes and equipment, engineering analysis; computer analysis; power
plant engineering, consultant, expert.
He
has had an impressive and verifiable list of industrial accomplishments
for 19+ years in validation, regulatory compliance, power plants
engineering and management. His validation and regulatory compliance record includes:
Summary:
William
Scherder is Director of Validation - Medical Device/
Pharmaceutical/ Biotechnology and Power Plant Engineering Services for TechnoBusiness Solutions.
He
is well known in the medical device industry since 1989. Developed
and reviewed equipment specifications, factory acceptance testing, engineering
studies, and qualification activities through process validation for
pharmaceutical packaging equipment and processes. Projects ranged from product/line extensions to new products/lines.
Developed and ensured adherence to project plans and schedules. Developed
validation strategies which included: protocol generation and execution of
engineering studies, commissioning, installation and operational
qualifications, and performance qualifications. These activities were related
to liquid, ointment, cream, and tablet filling / thermoforming lines.
Developed, performed and reviewed commissioning, installation and
operational qualification of simple GMP and non-GMP computer systems and
programmable logic controllers. Managed
up to 6 contract validation specialists hired to perform qualification
activities for pharmaceutical packaging equipment within the scope of an FDA
consent decree. Responsibilities
included: technical oversight, budget planning and scheduling.
Managed
the commissioning of utility systems for a new manufacturing building. Specific systems included: process water, HVAC, instrument
air, steam, chilled water, and miscellaneous process equipment.
Specific activities included: development of the project
commissioning template, commissioning strategy and protocol generation,
execution, and final report generation. Also responsible for content and review of all construction
turnover packages. Prepared
protocol and executed operational qualifications for clean steam generators,
autoclaves, equipment washer, and process tanks used in sterile process
manufacturing. Protocol
preparation and execution of commissioning documents, engineering studies,
installation and operational qualifications, and performance qualifications
of pharmaceutical packaging equipment utilized in liquid, ointment and cream
filling lines.
Managed and performed cleaning,
sanitization, and sterilization validation activities associated with a new
protein purification facility. Specific
activities included: protocol
preparation and execution, final report preparation and review, confirmation
of standard operating procedures and change control documentation. Designed
and executed an experiment to compare the difficulty of cleaning different
vaccine process intermediates. Utilized
this data to develop and promote a validation strategy that reduced the
planned number of validation studies by 50%.
Utilized the same data to demonstrate equivalency to existing
studies, eliminating the need for new small component cleaning validation
studies.
Prepared and audited regulatory licensing applications for vaccine manufacturing
facilities. Managed and
performed ongoing cleaning and sterilization validation activities for
vaccine production. Provided
validation expertise to a process reliability initiative team for a key
vaccine product. Executed
performance qualification, temperature mapping, and validation of controlled
temperature units and autoclaves.
Technical
Lead – Managed the
accident analysis functional area (FSAR Chapter 15) for power plants
operated by the Southern Company, a Westinghouse premier customer.
As a primary customer interface, proposed engineering solutions to
customer, conducted off-site customer training courses, supervised and
coordinated the activities of other engineers and technicians.
Performed thermal
hydraulic analyses of transients in nuclear power plants using a variety of
PC and UNIX based computer programs. Primary
function included computer simulation, preparation of engineering reports,
and 10 CFR 50.59 safety evaluations for the utility customer and the US
Nuclear Regulatory Commission. Developed
finite difference models for power plant steam generators.
Business
Unit Coordinator/Fluid Systems Analysis – Coordinated
computation, distribution, and approval of thermal hydraulic parameters for
power plant modifications. Position
required a significant attention to detail as the calculated parameters form
the basis for all analyses related to major programs.
Interfaced with all major engineering disciplines within the
corporation, and with the utility/customer personnel to reach consensus and
determine acceptable thermal hydraulic parameters that satisfied economic,
safety, design and contractual requirements.
Project
Management – Managed
external customer projects of varying size.
These projects required the teamwork of several internal functional
groups. Responsibilities included proposal of engineering solutions
to the customer, development of budget estimates, manpower plans,
supervision of analysis activities, preparation of final reports, and
ultimately the defense of the engineering approach and report to the
customer and the US Nuclear Regulatory Commission.
For larger projects, was also responsible for the coordination of
functional group activities, including the analysis strategy, and team
progress.
Regulatory/Licensing – Functional group expert for power plant modifications related to
instrumentation and control digital equipment, fluid systems and mechanical
component modifications and replacements.
Authored
licensing report sections, developed technical strategies and solutions,
authored safety evaluations, and safety assessment reports supporting plant
modifications and upgrades related to I&C, fluid systems, and mechanical
systems. Updated required
licensing documentation and defended changes to the US Nuclear Regulatory
Commission.
Functioned as the
Technical Lead for the verification and validation of the primary licensed
analysis computer model for the next generation advanced power plant.
Developed a successful technical approach, supervised computer model
modifications and team input to licensing documentation, authored licensing
report, managed schedule and defended to regulatory body.
Mr. Scherder worked at the University
of Pittsburgh
Material Science & Engineering
Department as a Graduate
Research Assistant – Designed an experimental apparatus for measuring the
mass transfer coefficients of polymer/monomer devolitization under a forced
flow field. In addition, He was
Graduate
Teaching Assistant for Mechanical Design Course and Lab Instructor for Mechanical
Measurements Course, both for the Mechanical Engineering Department, University
of Pittsburgh Medical Center
Clinical Chemistry – Lab technician (1987
– 1989)
Part time (20 hours/week) employment
while obtaining graduate degree.
Mr. Scherder has been received a M. S. Mechanical Engineering
and B. S. Chemistry, cum laude degrees from the
University of Pittsburgh. In addition, he has received a A. S. Biology
degree from the Community College of Allegheny County.
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