The 14f split cath was returned for evaluation.After decontamination, the distal end of the lumen was clamped.When flushed through the venous luer the solution came back through the arterial side, indicative of a cross lumen leak.A supplier corrective action request was issued to the contract manufacturer.The device was evaluated visually, functionally, and was crossed sectioned.The failure mode of a cross lumen leak was confirmed.A device history record review and a process review were performed.The investigation concluded the failure mode was due to improper assembly rods in the molding process.The failure was not detected during the 100% leak test that is performed at the end of the manufacturing process due to operator error.The machine used for the leak test has an alarm sound for when a failure occurs.This alarm was not activated.Actions taken include retraining of personnel on the hub molding procedure and updating the leak test procedure to include "active alarm verification".Device was used for treatment, not diagnosis.
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