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(b)(4).The customer returned multiple components of a psi kit, including the sheath assembly, dilator, obturator , and product lidstock.After meeting resistance during functional testing, visual examination revealed fogginess due to material buildup in the intersection of the side arm and stopcock.The material was tested via ftir analysis, and it was determined to be polycarbonate.No other defects or anomalies were observed.The outer diameter of the sheath measured 0.166" which is within the specification limits of 0.163"-0.167" per sheath extrusion graphic.The outer diameter of the side arm measured 0.132" which is within the specification limits of 0.130"-0.134" per side arm extrusion graphic.The instructions-for-use (ifu) provided with the kit informs the user, "prepare sheath for insertion by flushing through side arm." the returned sheath was flushed with water to functionally test the sheath.The sheath initially met significant resistance when trying to flush through the stopcock in the side arm.The side arm was then removed and flushed again, and it continued to meet significant resistance.A buildup of material was observed at the junction between the stopcock and sidearm.A lab inventory guide wire was used to break down the material, and then the sheath flushed as intended.Manufacturing was contacted to further analyze the sample.Manufacturing stated that they cannot assure that it is a manufacturing issue.They stated that the valve is 100% inspected with a blowoff test after gluing is dried.For this test, the air should flow freely through the extension line.If it does not flow freely, it is because the valve is clogged, and part is rejected.Further, when this part is completely assembled with the rest of components, a 100% inspection is carried out of vacuum test.In this same test, the piece is inspected at the end for contamination, scratches, imperfections, or cracks in the piece.Additionally, polycarbonate is not used in their manufacturing process.A device history record review was performed and no relevant manufacturing issues were identified.The ifu provided with this kit cautions the user, "some disinfectants used at the sheath insertion site contain solvents, which can attack the sheath material.Assure insertion site is dry before dressing." the ifu also states, "alcohol and acetone can weaken the structure of polyurethane materials.Check ingredients of prep sprays and swabs for acetone and alcohol content." the report of a blocked sheath was confirmed based on the complaint investigation.Visual examination revealed a fogginess at the intersection of the stopcock and sidearm.The fogginess was revealed to be caused by buildup of polycarbonate.The sheath passed all dimensional and functional testing after removing the polycarbonate, and a device history record review was performed with no relevant findings.Manufacturing confirmed that the parts are 100% inspected and polycarbonate isn't used in the manufacturing process.Based on the customer report and investigation findings, the root cause cannot be determined.Teleflex will continue to monitor and trend for complaints of this nature.
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