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The reported unused device was returned for evaluation in its original opened package.Label verification and visual inspection were performed.The device's short, straight seal was observed to have a seal area less than 1/4".Adjacent the device's defect area and male connector, the packaging was observed to have a tear.This defect resulted in a breach of sterility.Dye leak testing was performed on the defect seal area.Dye was observed to not penetrate the seal area.The packaging defect seal area was inspected for seal transfer.Seal transfer was observed to be less than 1/4" in the defect area.Due to the location and appearance of the defects, it is likely that the device was in the seal area during the sealing process and therefore a manufacturing related issue.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 were 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 3 complaints, regarding 4 devices, for this device family and failure mode.During this same time frame 15,573,370 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 0.0000003.It is standard medical practice to inspect all medical devices prior to use.This issue will continue to be monitored through the complaint system to assure patient safety.
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