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The device history record (dhr) for the reported lots was reviewed, and no abnormal process conditions were present during the manufacturing of the product that could have led to the reported condition.The dhr review showed that all acceptance criteria inspections per established sampling levels were within acceptable limits during the production process.A sample was not provided the device sample therefore it was not possible to conduct a physical evaluation.The customer did provide a photograph with a lot number which will be the only possible evaluation without having the actual sample.The review of the photograph showed that the balloon end of the device looks worn and possibly damaged.The customer did not specify how long the device was used on the patient, but a review of the picture showed obvious wear.The balloon end was discolored, and balloon damage was observed.Because this device was used for an unknown duration, it is subject to mishandling, manipulation, patient conditions, and/or degradation over time of use.Balloons will degrade from patient conditions and/or other factors that are outside of the manufacturer¿s control after its release.These devices are not permanent and require replacement over the time of use or as needed.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, equipment and milling machines.Additionally, there are procedures outlining general personnel requirements for cleanroom usage.To mitigate the risk of releasing nonconforming devices, each unit is 100% inspected at multiple steps of the manufacturing process and subject to a 100% balloon inflation tested during the process.Any defects observed during the manufacturing process will be segregated and scrapped accordingly.
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