Our previous example: 

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Issue - Open margin and open contact observed  in the patient's mouth, despite the model displaying a good fit.   

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Analysis - Upon cutting the impression, the root cause was identified. We informed the dentist that the soft body hardens faster than the heavy body, leading to deformation during dual impression taking. 

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Solution - Checked the expiration date of the impression material and switched to regular set impression material. Also, explained to the staff the importance of certain steps in the impression-taking process.