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Examination of returned unused device 139104ext found that there was an insufficient heat-seal.Examination was done with a dye leak test.A root cause cannot be determined, however, based upon evaluation of the device; a possible cause of this event could be that the device was improperly sealed at manufacturing.The manufacturing documents from the device history record have been reviewed with special attention to the manufacturing and inspection of the product.The product released for distribution was found to have met all specifications prior to shipment.This is the only complaint for this lot number and failure mode within the past two years.A two-year review of complaint history revealed there has been a total of 191 reports, regarding (b)(4) devices, for this device family and failure mode.During this same time frame (b)(4) devices have been manufactured and shipped worldwide.Should all the complaint devices have been found confirmed for this reported failure, the rate of failure would be 0.0002.Per the instructions for use, the user is advised the following: sterility guaranteed unless package has been opened, broken, or damaged.We will continue to monitor per regulatory requirements to help ensure patient safety.
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During incoming inspection, the distributor rejected this device, 139104ext accessory electrode coated blade with extended insulation, for an insufficient heatseal.There was no contact with the patient as this was found during incoming inspection.This report is being raised due to the reported malfunction with potential for injury upon reoccurrence.
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