Unless the manufacturers follow the car industry and real world test cars past the usual tollerances there will always be un forseen problems. .
Can't agree anymore except that although motor vehicle manufacturers do have to pass stringent tests including some safety ones for homologation, eg roll over etc its not those aspects that go wrong. Nine out of ten times it is one of the new features that is included that altered something or wasn't completely thought out. Even if they adopted HALT for components.
Manufacturers Vehicle Programme timing is squeezed tighterand tightereach time, driven according to management by "The Market". I've had vehicle programme phases that are delayed to the point of the next build stage of the project and that second stage isn't delayed so you end up with the same crap from the first one on the second. Vehicle Managament teams also adopt a "Oh thats a good feature you've come up with - I want it next week"
The other problem you face that in a large organisation like this there are many engineers working on these projects and somewhere down the line someone changes something small that has a big effect on another engineers components, without telling anyone. Who would have thought going from a 16MHz to a 20MHz Processor inside your Transmission Control Module would mean that your Instrument Cluster would now be reading 20% higher speeds! It all seems to work fine was the report I got.
Sad to say but things like this do slip through the net and end up in production and eventually with the end user - so a lot of the test date actually comes from the end user. I had 21 years in this field - frustrating as hell but everyday a unique challenge.
Now if we look at paintball products and the way they are deisgned, the number of Engineers working on a product is relatively small, in comparrision it's miniscule. Typically the Test Engineer is also the Designer. So he/she designs a product and it works within his own design brief. Opps forgot that they play paintball in the Arctic. I have always advocated that testing of a part should NEVER be done by the Engineer who designed it.
Paintball is not the multi-billion dollar motor industry so it must use the resources it has available or if it was and was investing pro rata you would find that your marker now costs the same as a new fiesta because of the relatively low volumes.
CNC programmes when you transfer them to China change tolerances?? Sorry I have to correct whoever said that - its the Relased Drawing that specifies the tolerance. The manufacturers ability to meet that tolerance can change but that's what a good QC procedure sets out to keep in check. Again these are not always perfect and are continually tweaked with improvements.
So unfortunately there will always be something missed. Hopefully they will always be small niggles and I agree that how a company deals with the customer in respect of these issues is by far the most important thing. Of course they must also learn the internal lesson at the same time. I for one would buy a Toyota now.