SAMPLE COMPANY Page 1 of 9 SOP # 05-1 Revision: 0 Prepared by: _ Effective Date: Approved by: _ Title: MASTER PRODUCT RECORD Policy: A Master Product Record will be prepared and maintained for all products manufactured or under development. Purpose: To prescribe the responsibilities for preparing Master Product Records (MPR) and to ensure the completeness of MPR Indexes. Scope: All products manufactured by the company are covered under this procedure. Definitions: 1. Master Product Record (MPR) - A compilation of records containing the description, design, formulation, specifications, complete manufacturing procedures, quality assurance requirements and labeling of a finished product. In addition to the Product specifications, a MPR contains documents that cover typical manufacturing activities including procurement, assembly, labeling, testing and inspection and packaging. 2. MPR Index - A table of contents for the master record of a product. It also can contain information on the breakdown of the product into assemblies and/or manufacturing steps. It is called a document plan during planning and early development of a new product. Procedures: 1.0 Preparation of Master Record 1.1 Upon completion of the design phase of a product, a formal document plan will be initiated and will be called the Master Product Record. The configuration and structure of the master record is determined by the Engineering and Manufacturing managers. After agreement, the master record will be created, document numbers assigned, status of drawings indicated and the record approved by Engineering and Manufacturing (See Exhibit 1 for a listing of items that may appear in a Master Product Record). 1.2 Upon compilation of all documents to be included in the Master Record, a MPR Index will be prepared to identify all items in the record and location(s) of these records (See Exhibit 2 for a sample MPR Index). MASTER PRODUCT RECORD Page 2 of 9 1.3 Complete specifications of the product will be prepared and included as part of the Master Record (See Exhibit 3 for items that may appear in a Product Specification). The product or product specification is a specific document that briefly describes and gives all important details of the external and optionally internal characteristics of a product. Generally a product specification will contain the Product's: - product trade and common name(s); - intended use(s); - performance characteristics and theory of operation; - regulatory classification; - physical characteristics; - environmental limitations and product stability; - important components and formula (if applicable); - manufacturing cautions; and - user safety characteristics. A preliminary product specification should be written at the beginning of a project and updated as the product is developed or modified. Specifications are usually developed by the marketing and product development departments with review and consultation by quality assurance, manufacturing, and other departments. The contents of the final specification must agree with the other elements of the product master record and with the actual product when it is manufactured. Before the start of full-scale production and commercial distribution, the product specification must be dated, approved, and placed under change control. In addition to defining and describing a product, a specification is a communication tool which, if used in a timely manner, can help achieve some important results. First, it helps assure that everyone is talking about the same product and working toward the same objectives with respect to safety, effectiveness, human factors, configuration, etc. Also, it is used as a guideline for developing test and inspection procedures for the finished product. Ultimately, the product specification or a condensed version of it should be used in catalogs, or other product documentation to aid communications between salespersons and customers. MASTER PRODUCT RECORD Page 3 of 9 The use of product specifications will result in: - improved communications between employees on a departmental and interdepartmental basis; - less confusion and increased morale; - an improved state-of-control; and - a higher probability of meeting cost, time, safety, effectiveness, and regulatory compliance objectives. Also, if the marketing department uses the specifications when preparing advertisements and catalog sheets, public relations with users will be enhanced because the marketing documents are based on proven scientific safety and performance claims for the actual product. That is, the user has an opportunity to read the technical specifications of the item actually being offered for sale. 1.4 As part of the product documentation, the Master Record will contain when appropriate specific written assembly procedures for constructing or fabrication of the product or sub-assembly components. These procedures are covered in the SOP for "Work Instructions." 2.0 Records Retention and Location 2.1 All records that pertain to a product shall be retained for a period of time equivalent to the design and expected life of the product, but in no case less than two years from the date of distribution. For products that may be repaired or capital equipment products that probably will be updated, records should be retained as appropriate to support these repairs or modifications. 2.2 Master records will be stored at the company's manufacturing plant and shall be readily accessible to the company's employees and to outside regulatory authorities (e.g., FDA, UL, Federal Government, etc.). The master product record must be a single source document or file. However, portions of this file may be kept in various locations. A master product record may exist as: - one or more files or volumes of the actual records containing the information required; - a reference list of such documents and their location; or - any combination of actual documents or reference lists. MASTER PRODUCT RECORD Page 4 of 9 These documents must contain the latest revisions, be signed, and be dated to show they have been checked for accuracy and approved for use. It is acceptable to maintain records on microfiche and/or microfilm reductions and discard the original hard copies, if the following conditions are met: - All reductions must be readily available for review and copying by investigators and designated company personnel at any reasonable time. - All necessary equipment must be provided for viewing and copying the records. - Reproductions must be true and accurate copies of the original record. If the reproduction process results in a copy that does not reveal changes or additions to the original record, the original must be retained. In this situation, the reproduced copy and any image shown on a viewing screen must note any alteration from the original and indicate that the original record is available. 3.0 Authorization and Change Control 3.1 The control of changes to products, processes and the associated master records is one of the most important elements of a quality assurance system. Any changes to the master product record must be authorized by the signature of the designated individual. MASTER PRODUCT RECORD Page 5 of 9 DOCUMENTS THAT MAY APPEAR IN A MASTER PRODUCT RECORD I. MASTER PRODUCT RECORD Index The MPR Index is a table of contents which is used for convenience. It may be known as a: Documentation of Master Record Unit; Documentation Plan; Product Tree; Documentation Index; Product Structure. II. Product Specifications III. Manufacturing Information A. Bill of materials (i.e., component list usually arranged by subassembly or other sub-product level or by process steps) B. Procurement documentation 1. Specifications 2. Drawings 3. Certificate of compliance requirements 4. Vendor evaluation procedures C. Product documentation 1. Fabrication drawings 2. Surface finish procedures 3. Subassembly drawings 4. Wiring and piping diagrams 5. Assembly procedures 6. Assembly drawings 7. Reference documentation a. Wiring and piping schematics b. Test specifications 8. Final formulation procedures EXHIBIT 1 MASTER PRODUCT RECORD Page 6 of 9 D. Precautions and special notations 1. Cleaning 2. Storage conditions 3. Hazards and safety precautions E. Equipment, lines, and procedures 1. Process lines 2. Assembly lines 3. Molds 4. Machine maintenance procedures 5. Calibration procedures 6. Setup procedures 7. Operating procedures 8. Process flow charts F. Production control documentation 1. Inspection procedures 2. Test procedures 3. Blank inspection/test forms 4. Instruments charts 5. Reporting forms 6. Approved deviations IV. Labeling and Packaging A. Labeling 1. Label drawings 2. Labeling drawings 3. Label/Labeling review procedures and forms 4. Production control procedures and history record forms 5. Instruction manuals 6. Service manuals 7. Customer feedback forms MASTER PRODUCT RECORD Page 7 of 9 B. Packaging 1. Package drawings 2. Closure drawings 3. Filling and/or packaging procedures 4. Packing procedures 5. Special shipment procedures C. Storage requirements 1. Temperature 2. Humidity V. Control Procedures and Activities A. Inspection procedures 1. Incoming 2. In-process 3. Finished products 4. Process control charts 5. Blank data reporting forms B. Test procedures 1. Incoming 2. In-process 3. Pretest conditioning 4. Finished product 5. Process control charts 6. Blank product history record forms VI. Final Release A. Release document B. Distribution procedures C. Blank Product history record forms MASTER PRODUCT RECORD Page 8 of 9 Prepared By: _ Approved By: _ Sample Company Master Product Record Index - Model 1000 Widget Current as of XX/XX/XX Location of Documents: Description Originals Working Copies I. Product Specification Mfg. File II. Product Literature (i.e. Brochures, etc.) Mfg. File III. Bill of Materials Mfg. File Purchasing/Engineering IV. Manufacturing Procedures(Assemblers Manual) Mfg. File Manufacturing V. Inspection and Q.C. Forms Mfg. File Manufacturing VI. Drawings/Schematics Mfg. File EXHIBIT 2 MASTER PRODUCT RECORD Page 9 of 9 _ ITEMS THAT MAY APPEAR IN A PRODUCT SPECIFICATION _ 1. Name of Product a. Trade name d. Chemical name b. Trademark e. Official name c. Generic name f. Common name 2. Performance Characteristics a. Description/Intended use e. Contraindications b. Accessories f. Input/Output requirements c. Functional parameters g. Human interface d. Limitations h. Other 3. Classifications a. Regulatory c. Functional b. Commercial d. Other 4. Physical Characteristics a. Weight e. Consistency b. Size f. Packaging c. Color g. Power requirements d. Form/Shape h. Other 5. Environmental Limitations a. Operating temperature f. Moisture protection b. Storage temperature g. Pressure, altitude c. Vibration and shock h. Electromagnetic interference d. Voltage limits i. Electrical transients e. Humidity j. Other 6. Important Components a. Active ingredients f. Service labeling b. Major subsystems g. Components supplied by user c. Diagnostic kit materials h. Software d. Accessories i. Other e. Labeling 7. User Safety and Performance Considerations a. Chemical e. Personnel training b. Electrical f. Periodic testing c. Heat g. Maintenance d. Sharp, moving parts h. Other EXHIBIT 3