01
Discovery, concept & candidate selection
Turning a target or an unmet need into a defined candidate: intended use, the population it serves, feasibility, and the early characterisation that decides whether to continue. It is where the product first becomes a specific thing.
The intended use written here propagates into classification, clinical design, labelling and the entire control strategy. Changing it later is not a document edit — it invalidates the reasoning built on top of it.
HOW IT FAILS
- Intended use is written loosely to preserve optionality, so downstream teams each interpret it differently.
- Selection criteria are applied after the candidate is chosen, documenting a decision rather than making one.
- Early characterisation data are generated outside any controlled system and cannot later support a filing.
WHAT CONTAINS IT
- A defined intended-use and target-product statement, under change control from the point it drives work.
- Pre-agreed selection criteria with the decision recorded against them, including what was rejected.
- Data-integrity expectations applied to early work proportionate to how likely it is to be relied upon later.
EVIDENCE IT OPERATES
- Target product profile and intended-use statement with revision history.
- Candidate selection decision records and the data behind them.
- Early study records retrievable and attributable.
02
Formulation & product design
Designing the thing itself: dosage form or device architecture, materials, components, specifications and the human factors that determine whether it can be used correctly by the people who will use it.
Design fixes most of the risk and most of the cost before manufacturing ever begins. A material chosen for availability, or a device whose use error was never studied, becomes a control burden that operations carries for the product’s whole life.
HOW IT FAILS
- Materials and components are selected without securing a supply position, so a qualified source becomes a single point of failure.
- Usability is assessed with people who already understand the product rather than the intended user under realistic conditions.
- Specifications are set at what the process currently achieves rather than at what the patient requires.
WHAT CONTAINS IT
- Material and component selection assessed for regulatory status, supply resilience and compatibility together.
- Human-factors evaluation with representative users, feeding identified use errors back into design.
- Specification setting justified against clinical relevance, with process capability treated as a separate question.
EVIDENCE IT OPERATES
- Design inputs and outputs with traceability between them.
- Material qualification and compatibility studies.
- Human-factors and use-related risk analyses with resulting design changes.
03
Analytical & measurement development
Developing the measurements the product will be judged by: what attributes matter, which methods can measure them reliably, and how those methods will be validated, transferred and maintained across the lifecycle.
Every release decision, stability conclusion and process claim rests on a measurement. A method that was never robust does not fail loudly — it produces plausible numbers that quietly widen the apparent variability of everything downstream.
HOW IT FAILS
- Methods are developed on one instrument by one analyst and only prove fragile when transferred.
- Robustness is evaluated at nominal conditions rather than at the edges the receiving laboratory will actually see.
- The method lifecycle stops at validation, so drift in performance over years is never detected.
WHAT CONTAINS IT
- Method development that defines the performance required before optimising to achieve it.
- Robustness studies spanning the conditions of the laboratories that will run the method.
- Ongoing performance monitoring across the method lifecycle, not a single validation event.
EVIDENCE IT OPERATES
- Method development and robustness reports with the intended performance stated up front.
- Validation and transfer packages with acceptance criteria and results.
- Trending of system suitability and method performance over time.
04
Process development & characterization
Understanding how the process behaves: which parameters matter, how they interact, what scale changes, where the operating range sits, and what control strategy holds the product inside its specification.
Process understanding is what makes validation an argument rather than a demonstration. Without it, an organisation can prove three batches worked and cannot explain why the fourth did not.
HOW IT FAILS
- Parameter ranges are inherited from the equipment used in development rather than justified by product impact.
- Scale effects are assumed linear, so a mixing or heat-transfer difference appears only at commercial scale.
- The control strategy is assembled at the end from what happens to be measured, not designed from what must be controlled.
WHAT CONTAINS IT
- Studies designed to find the parameters that matter, including the ones that turn out not to.
- Explicit scale-dependency analysis before scale-up rather than after a failed batch.
- A control strategy derived from the risk assessment and stated as a whole, not as a list of in-process tests.
EVIDENCE IT OPERATES
- Characterisation studies and design-of-experiment reports.
- Documented control strategy linking attributes, parameters and controls.
- Scale-up rationale with the effects considered and the data supporting it.
05
Quality by Design & development risk
Working from the target product profile backwards: which quality attributes are critical, what risk each carries, which experiments resolve the uncertainty, and how that knowledge becomes controls rather than a report.
It is the difference between a control strategy that can be defended and one that can only be described. Where the linkage from patient need to critical attribute to control is explicit, a change can be assessed; where it is not, every change is a guess.
HOW IT FAILS
- Criticality is assigned by consensus in a workshop and never revisited when data contradict it.
- Risk assessments are performed after development to document what was done rather than to direct what to do.
- The design space is described so broadly that it constrains nothing and justifies everything.
WHAT CONTAINS IT
- Criticality assessments tied to patient impact, revisited as data arrive.
- Risk assessment used prospectively to prioritise experiments, with the prioritisation visible.
- A design space bounded by data actually generated, stated with its limits.
EVIDENCE IT OPERATES
- Target product profile with critical quality attributes and their justification.
- Risk assessments dated before the studies they directed.
- Development report linking attributes, parameters, design space and controls.
06
Design controls & systems engineering
The formal engineering discipline for products developed under a device-style framework: user needs, requirements, design outputs, verification, validation, design reviews, transfer and the design history that records it all.
Design controls make the reasoning auditable — every requirement traceable to a need and to the evidence that it was met. It is also the framework a regulator will use to judge whether a design change was assessed properly years after the fact.
HOW IT FAILS
- Traceability is assembled retrospectively for an audit rather than maintained as design progresses.
- Verification and validation are conflated, so the product is proven to meet its specification but never that the specification meets the user need.
- Design reviews record attendance and approval without capturing the issues raised and how they were resolved.
WHAT CONTAINS IT
- A living traceability matrix from user need through requirement, output, verification and validation.
- Validation performed against user needs in the intended use environment, distinct from verification.
- Design reviews with independent participation and a record of issues and their resolution.
EVIDENCE IT OPERATES
- Design history file with inputs, outputs, reviews, verification and validation.
- Traceability matrix maintained through change.
- Design transfer records showing the design was reproducible in production.
07
Scale-up, technology transfer & comparability
Moving product and process knowledge to the site that will make it: assessing site fit, equipment equivalence, method transfer, scale differences and the comparability of what comes out the other end.
The receiving site inherits the outcome but not the reasoning. Where only the procedure transfers and the rationale stays behind, the site can execute the process but cannot judge what to do when it deviates.
HOW IT FAILS
- The transfer package documents what to do without the rationale for why the parameters are what they are.
- Equipment is judged equivalent by nominal specification rather than by the mechanism that matters to the product.
- Comparability is assessed on release testing alone, which is insensitive to the differences scale actually produces.
WHAT CONTAINS IT
- A transfer package carrying rationale, assumptions and known sensitivities, not just specifications.
- Equipment equivalence assessed against the operating principle and its effect on the product.
- A comparability protocol agreed before transfer, defining what would constitute a difference that matters.
EVIDENCE IT OPERATES
- Technology-transfer plan, knowledge package and gap assessment.
- Equipment and method equivalence assessments.
- Comparability data against pre-agreed criteria, and the acceptance decision.
08
Stability, shelf life & lifecycle planning
Establishing how the product changes over time and under stress, what packaging protects it, what shelf life and storage conditions follow, and the ongoing programme that confirms the conclusion holds.
Shelf life is a claim made to patients and regulators, and it is one of the few product attributes that cannot be re-tested after the fact. When stability is wrong, the correction is a market action rather than a document revision.
HOW IT FAILS
- Stability batches are made in a way that does not represent commercial material, so the conclusion does not transfer.
- Degradation is tracked against specification only, so a clear trend inside limits is never treated as a signal.
- Ongoing stability lapses after launch, and the shelf-life claim ages without confirmation.
WHAT CONTAINS IT
- Stability protocols on representative material, packaged as it will be sold.
- Trend evaluation against expected behaviour, not solely against the specification limit.
- A defined ongoing stability programme with a commitment to act on adverse trends.
EVIDENCE IT OPERATES
- Stability protocols, data and reports supporting the claimed shelf life.
- Packaging and container-closure integrity studies for the presentation sold.
- Ongoing stability results with trend assessment and any resulting action.
09
Development knowledge management
Preserving the reasoning behind the product: decisions taken, assumptions made, models used, experiments that failed, and the traceable record of why the process is set the way it is.
This is the knowledge that determines whether a change can be assessed in ten years. Losing it does not stop production; it makes every future change either unjustifiably conservative or quietly unsafe.
HOW IT FAILS
- Only successful experiments are written up, so the boundaries that failure established are lost.
- Rationale lives in slide decks and personal drives rather than in a controlled, findable record.
- Knowledge is packaged once at transfer and never updated as commercial experience accumulates.
WHAT CONTAINS IT
- Development records that capture assumptions, rejected options and negative results alongside conclusions.
- A controlled home for development knowledge that survives reorganisation and departure.
- Knowledge updated by commercial experience, so the package reflects what is now known.
EVIDENCE IT OPERATES
- Development reports including failed and rejected approaches.
- Controlled knowledge package with revision history.
- Records of commercial learning being fed back into development knowledge.