“Quality control systems should…”
Sorry- but those placards and qualifications are merely saying that your management is good enough that when they see a product in production that’s not working, they know enough to rework the design.
Look, I’ve been in product development for 35 years.
I’ve worked with bureaus running Stratsys printers for 25 years, and their $100K plus machines have as many problems if not more than any Form 2. And they have a long history of NOT supporting very expensive machines that are only 3 or 4 years old, too.
And, no, We don’t call it beta testing, because production runs are sold to the general public. But in today’s world of "pre-selling’, beta testing is exactly what it really is. When you pre-sell, you have forums threads like this full of folks who forked over money, trashing your company reputation for not delivering on time. That is a HUGE pressure to start shipping products that you know still have issues…
But in fact, NO complex product is fully finalized until AFTER it has been released to the public. And No complex product is fully designed until AFTER it has been put into mass production.
Products ARE routinely tweaked and altered while in production because of problems that only mass production conditions reveal.
It could be that human beings can not reliably assemble a part that there is no automated solution for. It could be that a part that TESTED fine, turns out to fail unpredictably earlier than the supplier warranted. It could be because a Part simply can not be made by anyone in the volumes the market requires… ( remember when Apple was promising Sapphire iPhone faces? )
And products being used in the real world reveal other issues that even the most conscientious team of quality control nerds never could have foreseen.
The old saying in product development is that you simply can not make anything foolproof, because fools are so very ingenious.