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What goes wrong

The user cannot open it

Updated

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A package nobody can open does not get used as designed. It gets left open, and then it protects nobody at all.

What people actually do

Leave the cap resting on the bottle, decant into a plain container, transfer a week of doses into something open, or ask somebody else to open it and then not close it properly. Every one of those is a worse outcome than an ordinary cap would have produced.

Which is why 90 percent is in the standard

The senior adult use effectiveness requirement exists precisely to stop manufacturers solving the child test by making the package impossible. A design that fails that threshold has failed, not compromised.

Hand strength and arthritis are the common cause

Push-and-turn needs simultaneous downward force and rotation, which is exactly the combination arthritis makes difficult. The population most likely to be taking daily medication overlaps heavily with the population least able to perform that action.

The one-minute retest is where this shows

Somebody can usually solve a mechanism given five minutes. Whether they can then repeat it in a minute is what predicts whether they will manage it every morning, and it is the part of the protocol that matters most for this failure.

Consider whether you need it at all

If the product is not required to be in special packaging and the household has no children, a reversible cap or an ordinary one may serve the user better. Fitting a CR closure because it seems responsible, to a product that does not need it, can reduce real-world safety.

Instructions on the cap, not in a leaflet

The molded arrow or text on the closure is what somebody reads at the moment they need it. A clear one is a meaningful part of the design and a faint one makes a workable mechanism feel impossible.

References

16 CFR 1700.15, Poison prevention packaging standards: child-resistant effectiveness of not less than 85 percent without a demonstration, and senior adult use effectiveness of not less than 90 percent. Special packaging must continue to function for the number of openings and closings customary for its size and contents. law.cornell.edu
16 CFR 1700.20, the test protocol. Children aged 42 to 51 months in three bands; panels of 50 rising to 200. Senior adults: 100 participants, 25 percent aged 50-54, 25 percent 55-59, 50 percent 60-70, 70 percent female, with a five minute and then a one minute period, and the package must be opened and properly resecured. law.cornell.edu
Written from the Poison Prevention Packaging Act regulations, not from a test laboratory. Child-resistant packaging is certified by testing a specific package as a system, and nothing here certifies anything. If you need a compliant package, the testing is the route and a matching closure is not a substitute for it.