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The device history record (dhr) file was reviewed, and no discrepancy was found according to the failure mode reported.The device was manufactured on june 10, 2021.One sample with an unknown lot number was received at the manufacturing site for investigation.A visual inspection was performed, and the reported condition was confirmed; a burst balloon was observed.This is a component purchased from an external supplier.A complaint notification was sent to the provider along with the sample to initiate the investigation.Per the supplier, the sample was evaluated, and the reported condition was confirmed.This incident is not considered an out of box failure as the device was used, obvious wear and usage were present.In further review of the balloon under a microscope and visual inspection, the balloon burst was 90 degrees to the left of the balloon inflation notch.Water was used to verify there were no obstructions and that there was a clear passageway for water and/or air flow.Due to the burst, the balloon could not be inflated.In review of any other abnormalities such as, voids, knicks, manufacturing defects, etc., there are no visual defects that definitively confirm the root cause.Because this device was used in the patient for an unknown amount of time, it is subject to mishandling, manipulation, patient conditions, and/or degradation over time of use.Therefore, the root cause cannot be confirmed.Additional possibilities that affect balloon life include unique patient factors such as diagnosis, treatment, surgical procedures, as well as medications, nutrition formulas, and gastric ph.Some patients also ingest food orally when the device is still in place which could also impact the balloon performance of the device.Current controls in place include training and certification on all manufacturing operations and qc inspectors as well as proper training on equipment used in the process.There are defined dimensional, visual, and physical requirements, testing methods and dhr/pics (pictorial instruction) provided at each workstation in the production line.Work instructions provide guidance for material verification, line clearance, and qc inspection sampling are followed.The manufacturing suite is maintained to the highest standards with rules outlining cleanroom operation parameters (i.E., temperature and humidity controls) and cleaning schedules for the cleanroom, lim equipment and milling machines.Additionally, there are procedures outlining general personnel requirements for cleanroom usage.To mitigate the risk of releasing devices with defects, each unit is 100% inflation tested during the process.The supplier will continue to monitor any trends to determine the need for corrective action.This complaint will be used for tracking and trending purposes.
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