Case Studies

Starting Point & Objective

The client had initial design input requirements, but no structured, audit-ready design control system in place. The goal was to develop a new device in compliance with ISO 13485:2016 and FDA 21 CFR 820.30, while ensuring that all activities were documented, traceable, and ready for review.

How We Supported the Project

1. Building a Structured Design Control Process

We supported the client throughout the development process by establishing a clear design and development framework. This included:

• a design and development plan with defined phases, milestones, and review gates
• development activities aligned with ISO 13485 and FDA requirements
• design reviews, risk management in accordance with ISO 14971, and full traceability across the project

This gave the client a practical and structured path from concept to documented design outputs.

2. Translating Design Inputs into Technical Specifications

Working closely with the client and key suppliers, we translated design inputs into clear technical requirements. This included:

• development of drawings, bills of materials, and material specifications
• definition of critical-to-quality characteristics and process requirements

By organizing inputs in a consistent way, we helped ensure the design could move forward on a strong technical basis.

3. Creating Design Outputs and Technical Documentation

Based on the agreed inputs, we developed the required design outputs and compiled them into a complete technical documentation package. This included:

• detailed product and process descriptions
• documentation prepared for CE and FDA submission pathways
• establishment of a complete Design History File (DHF)

The result was documentation that was not only complete, but also easier to review, maintain, and present during audits or submissions.

4. Planning and Executing Verification and Validation

Verification and validation were a critical part of the project. We supported the planning, coordination, and documentation of these activities, including:

• verification plans with defined test methods and sampling strategies

• testing performed in-house and through accredited laboratories

• biocompatibility testing in line with ISO 10993

• electrical safety testing in line with IEC 60601

• test method validation to ensure objective and reproducible results

All results were documented in accordance with Good Documentation Practice (GDP).

Challenges We Helped Solve

Challenge:  Fragmented design inputs from multiple sources.

Solution:  We addressed this through standardized specification templates, a traceability matrix, and structured review steps that improved consistency and transparency.

Challenge:  Parallel coordination of internal and external stakeholders.

Solution:  We supported this with clear responsibility assignments, an integrated project plan, and regular review points to keep progress aligned.

Outcomes

The project resulted in a complete, MDR- and FDA-compliant development file. By following a structured and standards-based approach, the client was able to meet regulatory requirements efficiently while avoiding costly rework. The client now has:

• a fully developed Design History File (DHF)
• traceable and verified design elements, from user needs through verification
• a strong foundation for regulatory submissions in the EU and US

Conclusion

This case study shows what effective design control can look like in practice: a development process that not only meets regulatory requirements, but also creates clarity, reduces risk, and supports submission readiness. Through a structured and collaborative approach, SIFo Medical helped the client turn complex requirements into a practical, well-documented development process.

Need support with design control or technical documentation?

SIFo Medical supports medical device manufacturers in building regulatory-compliant development processes, from early design planning through technical documentation and verification.

Let’s talk about how we can support your next project. Contact us at office@sifo-medical.com. 

Initial Situation

At the start of the project, significant gaps were identified across key quality assurance processes.

1. Manufacturing and Test Processes

A wide range of manufacturing processes and test methods were in use, but many had not been qualified or validated. There was also no structured approach to test method development, particularly for visual inspections.

2. Process Validation

Existing process validation activities were incomplete and did not meet regulatory expectations. Among the main issues were:

• no rationale for sample sizes
• OQ studies without clearly defined parameters
• no risk-based logic

An additional challenge was the need to align with the acquiring corporation’s validated standards, which were significantly more stringent than the client’s local procedures.

3. Equipment Qualification & Calibration

A large portion of the equipment inventory was either unqualified or insufficiently qualified. For example:

• ovens and climate chambers lacked temperature distribution studies

• microscopes and endoscopes had not been qualified

• many measurement devices were not calibrated

As a result, several test processes relied on equipment whose condition and performance had not been adequately demonstrated.

4. Visual Inspections

Visual inspection was widely used, but the underlying controls were not robust. Operators had not been qualified, including through visual acuity testing. Acceptance criteria were not clearly defined, and methods had not been developed or validated in line with applicable standards.

This was both an FDA finding and a key focus area of the corporate post-merger integration.

5. Multi-Site Challenge (USA & Germany)

Because the client operates sites in both the U.S. and Germany, the objective was not only remediation, but also harmonization. All processes needed to comply with FDA requirements, ISO 13485, MDSAP, and corporate SOPs.

Role of SIFo Medical

SIFo Medical was brought in to stabilize the situation quickly, address compliance risks, and support alignment with corporate requirements.

1. Team Setup & Scaling

Within a few weeks, a team of around 15 experts was assembled. The team was scaled up or down flexibly depending on project phase and FDA-related timelines.

2. Technical Focus Areas

Our work focused on the areas most critical to remediation and long-term compliance:

• Test Method Validation (TMV)

• Process Validation (PV)

• Equipment Qualification (EQ)

• SOP development and process harmonization

• coaching and training of employees

3. Building a Compliant Quality Framework

SIFo Medical revised and strengthened the relevant SOPs for:

• Process Validation

• Test Method Validation

• Equipment Qualification

These SOPs were designed to ensure full compliance with:

• FDA

• ISO 13485

• MDSAP

• the acquiring corporation’s internal standards

4. Operational Execution

In addition to improving the framework, SIFomedical also led the execution of the required activities. This included complete TMV, PV, and EQ projects, as well as overall leadership for validation and qualification work.

We established more robust and reproducible validation strategies, including justified sampling approaches, clearer OQ/PQ design, and worst-case rationales. Operator qualification was also strengthened, including vision testing and updated requirements for visual inspection processes.

5. Training & Change Management

To support implementation, intensive training sessions were delivered at the German site. This helped ensure that the new SOPs were not only written and approved, but also understood and applied in day-to-day operations.

Project Outcome

Over approximately 2.5 years, the client achieved a substantial uplift of its quality and validation systems.

FDA-related risks were systematically addressed and reduced. Corporate requirements were fully implemented, and QA processes were harmonized and strengthened across all sites.

According to the client, the company had “never worked with freelancers as competent as the team from SIFo Medical.” The project is regarded internally and externally as a benchmark for efficiency, compliance, and strategic execution.

Need support with quality remediation, validation, or post-audit recovery?

SIFo Medical supports medical device manufacturers in strengthening quality systems, closing compliance gaps, and building practical, audit-ready processes that work across sites and functions.

Let’s discuss how we can support your next challenge. Contact us at office@sifo-medical.com. 

Why Packaging Validation Matters

Packaging validation is essential to ensure that sterile barrier systems maintain integrity during manufacturing, transport, storage, and clinical use. With increasing regulatory scrutiny under the MDR, a robust, risk-based packaging validation strategy is more important than ever.

Our Approach to MDR-Compliant Packaging Validation

1. Product Categorization & Risk-Based Planning

We began by classifying all relevant products into logical packaging categories based on material type, size, and sterilization method. For each group, we developed a tailored, risk-based validation plan. Critical products were selected as worst-case representatives, ensuring compliance without unnecessary testing overhead.

2. Statistically Justified Sample Sizes (ISO 16269-6)

To define appropriate sample sizes, we used ISO 16269-6. This allowed us to base our test plans on real process data and variability. Our methodology included:

• Confidence interval estimation
• Tolerance intervals to account for outliers
• Test reduction strategies for proven process stability

3. Comprehensive Testing & Validation Activities

For each packaging category, we executed a structured series of validation steps, including:

• IQ, OQ, PQ  for heat sealing equipment.
• Test method validations such as:
  • Bubble leak test, dye penetration test, peel strength (ASTM F88, F2096, etc.)
• Accelerated aging studies following ASTM F1980 using the Arrhenius model
• Transport simulation tests based on ISTA 1A/2A/3A and ASTM D4169
  • Including drop tests, vibration, compression, and environmental simulations

4. Documentation & Collaboration

All validation steps were fully documented in accordance with Good Documentation Practice (GDP). We collaborated closely with the client and certified external laboratories to ensure both technical accuracy and regulatory compliance.

Results at a Glance

• Proven packaging integrity throughout the entire product lifecycle.
• Efficient resource use through representative product selection.
• Reduced testing effort via intelligent product grouping and risk stratification.
• Transparent, data-driven decisions with traceable documentation.
• Fully compliant with ISO 11607 and MDR requirements.

Conclusion

This project with Dr. Ausbüttel / Draco illustrates how packaging validation can be executed efficiently, without compromising compliance or patient safety. By combining international standards, testing, and risk-based planning, we delivered a sustainable validation solution for a broad product portfolio.

Are you looking for MDR-compliant packaging validation support?

We help medical device manufacturers meet ISO 11607 requirements with tailored, efficient solutions. Contact us at office@sifo-medical.com. 

Starting Point & Objective

Our client, a European medical device manufacturer, faced serious quality and compliance issues with a key supplier in Asia. A recent audit had revealed multiple critical deviations, triggering immediate action. The objective was to identify root causes on-site, remediate quality system gaps, and validate the manufacturing processes – in full compliance with ISO 13485 and MDR 2017/745.

Our Approach to Process Validation & Quality System Remediation

1. On-site Assessment & Gap Analysis

We conducted an in-depth assessment at the supplier’s facility to evaluate compliance gaps and performance issues.

Key areas of concern included:

• Missing or ineffective quality management processes
• Unqualified clean rooms and manufacturing equipment
• Lack of validated manufacturing and measurement processes

2. Strategic Remediation & Qualification Activities

Based on our findings, we implemented a tailored remediation plan:

• Hygiene management system: Design and rollout of a GMP-compliant hygiene concept
• Clean room qualification: Per ISO 14644 standards
• Measurement method development & validation:
  • Geometric measurement of injection-molded parts
  • Force measurement for welded components
  • Optical evaluation of assembly features

• Process validation:
  • Injection molding of 12 components (up to 8 cavities per mold)
  • Ultrasonic welding of complex assemblies
• Introduction of:
  • A structured change & deviation management system
  • A hygiene monitoring ring for routine oversight

3. Transparent Communication & Collaboration

Throughout the engagement, we kept the client closely informed via weekly progress calls. This ensured transparency, aligned expectations, and helped foster trust across all stakeholders. We used proven tools and methodologies such as Six Sigma to analyze root causes, optimize processes, and ensure statistically sound validation outcomes.

Challenges & Solutions:

Challenge: Significant cultural and language barriers impacting supplier communication.

Solution: On-site presence, bilingual experts, and culturally adapted training methods.

Challenge: Non-existent documentation of critical processes.

Solution: Creation of audit-proof process validation protocols and test method justifications.

Challenge: Lack of measurement capability for process outputs.

Solution: Custom development of measurement systems with Gage R&R validation.

Project Outcomes:

• 60 % reduction in complaint rate due to improved process control aligned with MDR and ISO 13485.
• All audit deviations closed within 12 months.
• Audit-proof documentation.
• Strengthened supplier relationship based on mutual understanding and trust.

Conclusion

This project demonstrates how process validation – when embedded in a broader quality remediation strategy – can transform even critical supplier risks into operational strengths. With clear structure, validated methods, and a collaborative mindset, our client now benefits from a compliant, reliable, and efficient supplier in Asia.

Do you need support with process validation or supplier remediation? We help MedTech companies ensure compliance and performance across their supply chain. Contact us at office@sifo-medical.com. 

Starting Point & Objective

A medical device manufacturer contacted us urgently after an audit finding revealed missing test method validations (TMV) in their quality system. The audit report highlighted a compliance gap regarding ISO 13485 and FDA 21 CFR 820.80 requirements for validated inspection, measuring, and test equipment. The objective was clear: Quickly establish compliant TMVs for critical product tests, with minimal disruption and maximum regulatory confidence.

Our Approach to Fast & Effective Test Method Validation

1. Immediate Access to the TMV Online Guide

To provide rapid support, we gave the client direct access to our TMV Online Guide, which includes:

• Pre-validated templates for test method validation protocols and reports
• Checklists aligned with ISO 13485 and FDA requirements
• Step-by-step video instructions for correct application
• Guidance documents for understanding Gage R&R, accuracy, repeatability, and more

The client only needed to fill in their specific test data – all structure, wording, and regulatory alignment was already taken care of.

2. Personal Expert Support

In parallel, we supported the client with targeted consulting to answer open questions and review their draft documentation.

Thanks to our efficient format and hands-on experience, we helped the team:

• Select the appropriate validation method
• Define acceptance criteria
• Justify sample sizes and test design
• Understand how to interpret and document the results

Challenges & Solutions

Challenge: Time pressure due to an upcoming follow-up audit
Solution: Instant access to ready-made templates, eliminating delays caused by blank-page syndrome

Challenge: Lack of internal expertise on TMV requirements
Solution: Step-by-step video explanations and expert Q&A support for each stage

Challenge: Concern about audit acceptance.

Solution: Templates and validation logic aligned with ISO 13485, FDA 21 CFR 820, and GHTF guidelines – ensuring audit-proof documentation.

Project Outcomes

• Full TMV package completed within days.
• Audit deviation closed successfully and sustainably.
• Compliant and traceable validation of critical test methods.
• Improved internal know-how for future validations.

Conclusion

This case demonstrates how fast and effective Test Method Validation can be – when the right tools and expert guidance are in place. Our TMV Guides enabled the client to meet regulatory requirements, close an audit finding, and build a robust validation framework in record time. 

Starting Point & Objective

elm-plastic GmbH, a medical device manufacturer, approached us with a clear challenge: justifying the sample sizes used in their process validation. Since sample sizes are derived from risk management, we first needed to implement a strong risk management system. This system was designed to comply with ISO 14971 and other relevant regulations, while also improving internal processes for greater efficiency.

Our Approach to Risk Management Optimization

Comprehensive Assessment

We began with a thorough evaluation of elm-plastic GmbH's existing risk management framework, identifying areas for improvement and ensuring alignment with current regulatory requirements.

Customized Risk Management Framework

Based on our assessment, we developed a tailored risk management framework that integrates seamlessly with their existing quality management system. This included:

• Development of risk management procedures and templates compliant with ISO 14971.

• Training sessions for key personnel to ensure proper implementation and understanding of the new processes.

• Integration of risk management activities into the product development lifecycle.

Ongoing Support and Consultation

Throughout the implementation process, we provided continuous support and consultation to address any challenges and ensure the successful adoption of the new risk management system.

Challenges & Solutions

Challenge: Aligning existing processes with updated regulatory requirements.

Solution: We provided a clear roadmap and practical tools to bridge the gap between current practices and regulatory expectations, facilitating a smooth transition.

Challenge: Ensuring staff engagement and understanding of new risk management procedures.

Solution: Conducted interactive training sessions and provided user-friendly documentation to promote comprehension and buy-in from all stakeholders.

Project Outcomes

• Enhanced Compliance: elm-plastic GmbH's risk management processes are now fully aligned with ISO 14971 and other relevant regulations.
• Improved Efficiency: Streamlined processes have reduced redundancy and improved overall operational efficiency.
• Empowered Team: Staff are better equipped with the knowledge and tools necessary to manage risks effectively.

Conclusion

This collaboration between elm-plastic GmbH and SIFo Medical demonstrates the value of a structured and customized approach to risk management in the medical device industry. By focusing on compliance and efficiency, we helped elm-plastic GmbH enhance their risk management processes, ensuring better outcomes for both the company and the patients they serve.

Need support with process validation, sample sizes, or risk management?

SIFo Medical supports medical device manufacturers in strengthening quality systems, closing compliance gaps, and building practical, audit-ready processes that work across sites and functions.

Let’s discuss how we can support your next challenge. Contact us at office@sifo-medical.com. 

Initial Situation

Fresenius Kabi’s quality team in the Dominican Republic was looking for more than a generic training. They needed a Test Method Validation program that connected directly to their daily work in medical device manufacturing.

Two requirements stood out:

• Practical relevance. The training had to address their actual processes, not abstract case studies.
• Recognized certification. Participants needed a credential they could point to – both internally and during audits.

The Solution

We proposed a structure built around a simple insight: training only sticks when people apply it to their own work. So we split the program into two distinct days.

Day 1: Certified TMV Training

The first day delivered the full Test Method Validation curriculum, concluding with official certificates for every participant.

The content covered:

• Introduction & Fundamentals: regulatory drivers and hierarchy, test types and data categories, essential validation prerequisites.
• Planning the Validation: triggers for validation and revalidation, building a complete TMV plan, defining parameters and acceptance criteria.
• The Study in Detail: accuracy, precision, trueness, and bias; designing studies for variable and attribute methods; analyzing variation and Gauge R&R results.
• Documentation, Data Analysis & Reporting: data collection, blinding to reduce operator bias, accurate analysis and interpretation of TMV data.
• Life Cycle Management: full life cycle phases, ongoing monitoring to maintain method validity, risk-based revalidation and change management.
• Summary & Practical Tips: consolidation of key concepts, application to real-world scenarios, and next steps for continuous improvement.

For most participants, this alone would have been a strong training. But the real shift happened on Day 2.

Day 2: Live Process Review and Q&A

On the second day, we put the slides aside. Our CEO Simon Foeger worked directly with the team on their own processes, their own test methods, and their own open questions. Every participant could bring forward the validation challenges they were actually facing and get a direct, expert answer.

This is where the format earned its strongest feedback. Participants moved from understanding TMV in theory to seeing exactly how to apply it to the methods they work with every day.

The Outcome

The training was delivered on December 10, 2024 – three months after the initial inquiry, scheduled to align with the client’s preferred timing. All 20 participants completed the program and received their certificates. 

The feedback was outstanding. One participant captured it best: