I don't know how many here have worked a factory job but I worked a few in my youth. ISO 9000 certified all. Here's the deal fellas- Repair is cheaper than QC. Period. I'm sure a formula exists but I'll just explain-
Paying someone to go over every single piece costs money. That's an hourly wage every day all day to at least one but usually 3 or more people. Even at $10 an hour it gets expensive. Most companies (even ISO 9000 certified) check batches. That could be anywhere from 1 in 10 to 1 in 100 or 1 in 1000. It's different everywhere.
You make a product that even if it fails probably wouldn't kill anyone so not a lot government oversight exists. You also have a reputation for quality that was built over many years but production and the cost of materials has went up. You make 100 bad pieces out of 200 but those 100 are functional, but heavily flawed. Years ago this would have never left your factory, but just tossing those pieces creates too much loss. So even though you know those pieces may not be up to snuff you send them out anyways.
Those 200 pieces get bought. You have complaints but not about all 100 bad pieces. Some people don't know what to expect or have no frame of reference besides gas station crap. Some don't care because they bought "X" brand and they ROCK and are blinded by the love. Then you have the guys, well the type that come here.
You love the brand as you've come to trust them. Maybe they were the first knife that you bought that didn't cost $5 and come with a free shirt. But you can't let those flaws go, as you've come to expect a certain amount of fit and finish. Do you send every knife back? No, damn it. That adds cost to the knife and it should have been caught at the factory so you mostly fix it yourself. Then you get one that's so bad you have to say something because only a mentally disabled person would think this was OK to leave the factory!
So you come here and post. People say either "Me too." or "No way, mine have been great!". So begrudgingly you send it in thinking maybe this is a one time deal. But it's not. That's why guys get 2 out of 6 or 10 out of 40 that were flawed.
Now you have one guy or two that deal with returns. It's probably not their only job, many did other jobs like janitorial work or even ran machines when there were no returns. They inspect the product and either fix it or just replace it with a cherry picked product. You send them a list of everything that's wrong with the product, they don't even have to try to figure it out themselves! They ship it back and you're a happy camper never knowing that you are actually the QC department and you just paid a company to be so. These repair guys don't have to worry about batches and production doesn't miss a step. Modern production has been about speed and efficiency for a while now with QC taking a back burner.
So what does this mean? Complaining will probably get you nowhere. Sorry. Maybe 1 in 10 or 1 in 50 actually come back for repair, that leaves a lot of pieces that would've been thrown away out in the wild. That means less waste and more money. I worked my way to supervisory positions at every place I've ever been employed and once I got there the veil was lifted to some unbelievable and even scary stuff at all of them.
What all of these companies hope for is that it doesn't come back to bite them in the rear, you know like a certain airbag company. Certain knife companies have went down because of this need for speed instead of a need to get it right. Gerber is a perfect example. I saw a Press Release by Gerber a while ago about a individually numbered special edition knife that would cost pretty far up on the scale for them that made me sad. They were acually proud of this turd! Bad grinds, poor fitment, they must of not realized that resolution is the enemy to hiding poor fit and finish. They traded quality for quantity and now they're a laughingstock. I wouldn't buy a Gerber with someone else's money let alone my own.
Nothing will change as this is the world we live in today. It's OK to be frustrated and voice your concerns. Just don't expect miracles guys. And always check before you buy or have the company you're buying from check for you. You'll end up happier that way
PS- Sorry for the long winded post but I read the whole thread and thought I could give a little insight.