XS Scuba Miflex Hose FAILURE

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Try stretching the remaining o-ring to see if it's crispy/cracking. If not, user install error.
 
I like the hose to only be hand tightened to the second stage for my tech rigs. If I am careless and start the dive with the hose backed off, it might very well start leaking during the dive. If I simply tighten the hose down at that point, it cuts the o-ring in a manner similar to the pictures you posted. I have learned to turn off the tank, depressurize the system, fully back off the hose and then re-attach. You won't cut the o-ring that way and ruin your dive. Since I dive side mount a lot, this is not a big issue for me.

On OW regulators, taking care of the situation is much harder since you only have one tank. Consequently, I snug the hose down with a wrench to keep it from ever backing off. Don't overdo it and use two wrenches in order to keep from cracking a plastic bodied reg. You don't need much pressure to keep it from backing off: just a snug.
 
I have seen this happen, even had it happen to me before. Basically when the 2nd stage is installed, sometimes the O-ring gets pushed out of the grove, then when it is screwed in, gets cut by the threads. It's one of those "It happens" type things. I agree that just having a few spare .010 rubber O-rings & a pick would fix the problem in about 2 min.
 
https://www.shearwater.com/products/swift/

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