QUALITY AND CONTINUOUS PROCESS IMPROVEMENT

NEW PRODUCTION & MANUFACTURING & CONTINUOUS PROCESS IMPROVEMENT FOR YEAR 2022

Quality and Continuous Process Improvement plan on Ultrasound Gel & ECG Gel production

ISD Meditech Sdn Bhd (“ISD”) had been manufacturing Ultrasound Gel & ECG Gel for the past 12 years with the brand name “ SKY GEL”.

ISD never stop on continuous innovate, develop and improve on all aspects, including products, processes, manufacturing and production. Indeed, ISD had expand its manufacturing plants and investment on producing high quality ultrasound gel.

The past many years experiences on producing this Ultrasound Gel which is Medical Device consumable item which had been approved by Malaysia Medical Device Authorities (MDA), Kementerian Kesihatan Malaysia/ Ministry of Health Malaysia (KKM) and also CE Certified by Medical Device Safety Service GmbH, ISD always ensure that the product that we produce must be with high quality and free from any microbial growth.

 

1a. LABORATORIES TEST

SKY GEL products “PASS & APPROVED” the following test required by Malaysia Medical Device Authorities (MDA):

No.   TESTS
1. AGING AND STABILITY TEST / SHELF-LIFE TEST (ACCELERATED) according to ASTM F1980-02 (Standard Guide for Accelerated Aging of Sterile Medical Device Packages)
2. Dermal Sensitization Assay Test
3. Primary Skin Irritation Test
4. Test for Cytotoxicity

view here

 

We always take precautions steps and extra test to ensure that our products do not has any microbial growth with daily laboratory Test report. We take our own initiative to test on the following full report 8 parameters perform on Accredited BP (2019) Appendix XVI Lab test: Daily Lab Test Record Jan-Mar 22.pdf

  1. Total Aerobic Microbial Count
  2. Pseudomonas Aeruginosa
  3. Staphylococcus aureus
  4. Aspergillus Niger
  5. Burkholderia Cepacia
  6. Salmonella
  7. Escherichia Coli
  8. Clostridum Perferingens
certificate

In addition, ISD does send further Lab test on SKY GEL Ultrasound Transmission Gel show that the product free from microbial growth performed on [USP60 <microbial examination of non-sterile products – test for Burkholderia cepacia>]

In order to ensure the safety and quality of SKY GEL Ultrasound Transmission gel. We had conducted the Preservative effectiveness TestView here : Preservative effectiveness Test on Burkholderia cepacia. During the course of 28 days preservative effectiveness test on Microbial study, samples of SKY GEL  was undergo single challenge test by laboratory to simulate the conditions in a SKY GEL Transmission Gel.

Samples under challenge conditions met the microbial examination of non-sterile products – test for Burkholderia cepacia criteria. As long as a bottle that has been opened is stored properly in room temperature and not contaminated during use, the gel is expected to maintain its original shelf life.

1b. QUALITY PROCEDURES

ISD always strive to ensure Quality of the products and stringent quality assurance procedures include the following:

  • Environmental monitoring program monthly tests several areas of the manufacturing and production areas for microbial contamination, including manufacturing and packaging equipment;
  • Sanitizing manufacturing machineries and production areas daily;
  • Microbial testing is performed monthly on the process water used to make all SKY GEL products and results have shown no presence of bacteria at all points of use;
  • Sanitization of entire process water system is performed monthly;
  • Continuous monitoring of water quality provides real-time indication of any system malfunction;
  • Microbial testing is done on all SKY GEL products during the routine stability program every six months throughout the life of the product. There have been no indications of microbial growth;
  • Pathogen testing on all production batches on SKY GEL demonstrates product is free from pathogens when manufactured.

1c. QUALITY ASSURANCE COMPLIANCES & COMPETENCY

We had identified on how to continuously improve our process on medical device quality thru strict regulation compliances and training on staffs:-

  1. Quality assurance through Regulations & Audit

    As healthcare companies are becoming more inclined to value-based patient care, regulatory bodies have tightened the compliance requirements to increase transparency and ensure medical device quality and efficacy. With stricter norms and greater emphasis being given to patient safety, medical device manufacturers must establish processes to achieve compliance. ISD had obtained ISO13485 certification audited by TUV, Rhineland LGA Products, GMBH certification body and CE certification by Medical Device Safety Service GmbH. We also obtained approval from Malaysia Medical Device Authorities (MDA) and Good Manufacturing Practice Certificate (GMP) on all SKY GEL  products.

    QA Compliances > view here

  2. Creating culture of quality and staff competency in the organization

    Quality begins with every employee and includes every process and procedure ranging from development to delivery. This involves implementing robust quality standard processes across the business. By improving quality across operations and establishing a comprehensive control mechanism, medical device manufacturers can cultivate a culture of quality. ISD provide training to all staffs enable them to equip with the ISO 13485 and ISO 14971:2019 Risk Management
    for Medical Device knowledge.