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The lot history file was reviewed for d808013.The work order was for a lot of 30 stabilizers.All required paperwork was present and complete documenting that the stabilizers were manufactured and inspected per procedure.All units passed the required inspections.Stabilizers undergo a 100% packaging inspection which includes 8 different inspection points related to the feet on each unit.During the inspection, it is verified that the o-rings are present as the o-rings are used to secure the feet to the device.There is also a 100% post-sterile inspection and a 100% visual pre-shipment inspection in place to look for this defect.All 3 inspections took place and are recorded.The probable cause of this defect based upon 2 prior investigations, is that the o-ring sustained a minor stress during the assembly process which was not visible during the inspections.The o-ring likely broke in transit allowing one foot to become dislodged.The foot and o-ring likely remained in the tray and were discarded when the stabilizer was removed.The incident rate of this failure type, specifically after the device has been through the 100% inspections if very low but possible.This potential failure mode is already identified in the fmea and is known to the assemblers.This is the 11th complaint of a split o-ring since the 2008 investigation and the 3rd since the 2016 investigation.We will continue to monitor for further occurrence.
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