An industrial approach towards solid dosage development for first-in-human studies: Application of predictive science and lean principles

•Scientific, knowledge-based, predictive product development towards digital design.•A simplified lean approach enabling efficient and rapid product development.•A systematic approach to development of first in human oral dosage form.•Combining material-sparring methods and modelling to deliver robust formulation. Tablet development is challenging during early clinical phases of drug discovery because of dose uncertainty, limited active pharmaceutical ingredient availability, and short lead times. Here, we introduce a new framework to expedite product development using a suite of in-house and commercially available predictive tools developed through the integration of computer modelling and material-sparing characterisation methods. The strategy underpins the use of dry granulation for formulation development with guidance on scale-up and manufacturability to achieve ‘First Time Right’. We present an analytical strategy based on predictive science with a focus on stability, and shelf-life related attributes to assure product quality. Thus, we provide a holistic approach towards robust, scientific product development through integrated project knowledge and risk-based approaches, delivering significant savings in both material and resources. An overview of formulation, analytical, and manufacturing strategies applying predictive tools and using science- and risk-based approaches for robust design benefitting patients and taking formulation development towards digital design.