The reporter noted the patient required medical treatment and a tracheostomy (trach) change out due to the event.Therefore, the report is considered a serious injury instead of a malfunction.Device evaluation: one portex suctionaid sample was received in used condition without its original packaging.Immediate visual inspection noted a leak in the cuff of the sample.A leak and inflation test was completed and a leak was detected.The cuff assembly operation and inflation line assembly were reviewed to ensure operators were properly performed and that devices are manufactured correctly with no discrepancies.Samples were audited during thirty two (32) units finding no issues and no deflated cuffs.A review of the manufacturing process was conducted and was considered adequate and correct.Based on the evidence and investigation, the complaint was confirmed.The problem source was stated to be unknown.
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