Pre-Operational Validation of a Deviation-Ready QMS for Source Plasma Centers: Readiness Metrics and Hematology Supply Implications

Source plasma centers sustain hematology therapeutics by safeguarding testing, traceability, and cold-chain integrity before fractionation. Despite regulatory requirements (21 CFR 606/640; EU Directive 2005/62/EC), published pre-operational validation frameworks demonstrating deviation-readiness before first collections remain sparse. We conducted a simulation-based pre-operational validation of an electronic quality management system (eQMS) with an Incident → Deviation → Corrective Action and Preventive Action (CAPA) pathway at a new source plasma center, performing 20 chairside mock runs, 3 freezer-alarm drills, and a document-control stress test. Primary endpoints were anomaly rate, alarm-response time relative to a 15 min service-level agreement (SLA), and deviation-closure SLA compliance. Analyses were descriptive and designed to demonstrate system functionality, not long-term process stability. Minor anomalies occurred in 6/20 mock runs (30.0%; 95% CI 11.9–54.3); no major/critical events were observed (0/20; 95% CI 0–16.8). Deviation-closure SLAs were met in 6/6 tests (100%; 95% CI 54.1–100). Alarm-response times averaged 7.0 min (SD 1.0; range 6–8 min; 95% CI 4.5–9.5), and all drills met the 15 min vendor SLA, illustrating a preliminary readiness margin (Cpu ≈ 2.7) rather than a statistically stable capability estimate. Simulation-based pre-operational validation produced inspection-ready documentation and quantitative acceptance criteria aligned to U.S./EU expectations, supporting reproducible multi-site deployment. By protecting cold-chain integrity and traceability before first collections, the validated QMS helps preserve supply reliability for plasma-derived therapeutics central to hematology care and establishes the measurement infrastructure for post-operational performance validation.