It's a fact that the knife industry is a cut throat business at best. That's why Schrade, Camillus, and a host of old marques are no longer with us. The cost of new tooling is high, and that's what I think killed Schrade in the end. The tooling was shot, no capability of holding any kind of tolerance, and sloppy stuff was going out the door. Some of the Schrade branded stuff I saw the last few years they were operating was horrible.
I hope Case doesn't take that route, but they need to increase their QA a bit, even if they have to charge a few dollars more. I'd pay another couple bucks for a hand inspected knife, and I'm sure you all would. Heck, how much do you pay for a GEC? Double? Almost triple in some cases? (No pun intended!)
A lot of this comes from imperfect parts to start with. The basic frame, the spacers, bolsters, and back springs are the same for a lot of models. The Texas jack and same size stockman, for example. If you have perfectly blanked and machined parts, it's a heck of lot easier to make a perfect assembly. Like Victorinox. Like Harley Davidson motorcycles. When Harley was dumped on the market after AMF bled them dry like a vampire, nothing much was left. AMF had just kept shoving bikes out the door that had been made on ancient machinery, out of spec, and failing before they were out of warrantee. In 1984 when they re-organized and they knew it was their last shot, they sent a survey team to Japan to see how it was done. They then made a huge gamble and investment in all new Japanese machining centers and laser guided cutting tools, and huge increase in QA. The result was, they actually made a better motorcycle that could compete with the more reliable Japanese and German bikes. They did what thad to be done, invest some time and money into the company, re-train employees that failure is not an option.
If people are willing to spend 100 dollars for a GEC, then maybe Case has to boost the price of a 40 dollar knife to 45 or even 50, and have the final QA inspectors on the line look over each and every one before it goes out. They need to do something, because when somebody here's about how Case used to be THE knife that their granddaddies carried, and they go out and buy one, and it comes looking like a refuge from scrap pile, you think they will ever buy another one? They'll go buy some other brand. Maybe Case needs to stop with the 85th Elvis birthday and name brand farm tractor commemoratives, and just make darn good using knives.
Maybe they need to send a survey team to Switzerland.