I wonder if you could add 10# of something to the seat without affecting the comfort too much. Maybe hang something off the bottom of the seat to help offset the problem?
You would have to be pretty creative to do this. There's not a lot of room under those seats for you to place a 10lb weight. Also, you would need to make sure it was securely fastened with some high quality stuff, because if you get in an accident with a 10lb weight just hanging under your seat, it's bound to create some more problems. Even then, if you don't get the weight in the correct position, it would be useless. The weight sensor isn't under the seat above the floor plan, it's built right into the seat. Underneath the cushion pan generally bolted on above the slide rails. If you attached it to something that was built directly into the frame structure and not the cushion structure, the weight wouldn't even show up on the sensor.
Every ODS/OCS is calibrated/tested on the assembly line to fit the seat it's being built onto. There is a station at the end of the line that plugs into the seats and will make sure it's all calibrated within the specs given by the OEM. But all it takes is someone bumping the wrong piece on a seat and it can throw that calibration off. So it is definitely possible your seat is mis-calibrated, however it's much more likely that the person is just too light. There is no federal requirement for weight, but it's actually classified as the 5th percentile for adult females. Which I believe with the dummies I have used, weighs in right around 108-110lbs. So your child is literally right at the limit for what the OCS will detect.
You don't have a defective seat, just a flawed detection system.
Signed,
A seat engineer.
PS, if your child is leaning on the console/armrest in the door, or is slouched in the seat at all, this will take even more weight off of the sensor. Hence why I said it's a flawed system, but not a flawed seat.