bit_bucket
macrumors 6502
People seem to think that every single unit produced goes through a manual quality control person who checks every switch, glass leveling, light leak... I hardly think this is the case.
I have spent exactly zero time researching mass electronics production in Chinese factories, but to think that every single unit is checked is just ludicrous. This could simply be that the factory did not produce the item even to Apple's spec. Do you think Steve sits there and opens every one of the millions of phones produced and looks over them?
If Apple approved of the quality, they would not be replacing them for free for something as minor as tiny scratches in the chrome. They would tell you that's just part of the manufacturing process. They ARE taking them back for even the most mundane of "problems". That, to me, shows that they actually do care that you get a good product.
As several others have said, it seems like a massive manufacturing problem because phone geeks who find even the slightest imperfection with their phone will flock to a site like this to complain. To many people, their phone is what defines their existence. People who have good phones, people who simply don't care, and the hundreds of thousands of people who do NOT come to internet forums will never be heard from. You hear lots of noise from the tiny percentage of people who do have problems, so it sounds like a major problem.
As someone who previously worked on computer systems used in the manufacturing of automotive electronics and safety equipment, I can tell you that in the US, every part is checked. EVERY part goes through either an infrared, xray, photographic scanner and anything that is out of spec, even down to minute cracks in say the casing of a car radio causes the device to be rejected and scraped. Now if the US can do it, then why the heck cant China?
Apple has gone from a nitch manufacturer of great devices that were quality, to a more mainstream manufacturer of great devices that are kwality with a k. That being said, I am going to keep on using my semi defective macbook pro and my cracked iPhone 3G, because the replacements will be worse.