OUCH! I have a mental image of a deflated balloon
with a big R on it.
Matt and Bob, I couldn't agree more. Quality Assurance/Quality Control is a problem at most gun companies today. But, from the point of view of a manufacturing guy, I believe the heart of the problem is in the PHILOSOPHY and CULTURE of the companies not so much QC/QA specifically.
Quality CANNOT be "inspected" in after the parts have been made. Integrated manufacturing and quality assurance practices are essential. If you're catching the out of tolerance parts after they've been made you are forcing yourself to decide between throwing them in the scrap bin or sacrificing product quality. Neither is a good or sustainable option.
The problem is a PROCESS problem, and a CULTURE problem. A process that always yields the desired result, every time, should be the only acceptable answer.
Develop the best process for a given component or operation. Document that process so that each time it is performed it is performed the same way, regardless of who's doing it. Create the quality process and the manufacturing process in tandem and make sure they work together in harmony.
The QA department is not the bad guy, but all too often they are forced into the role of being the "Quality Police". QA should be regarded as manufacturing's best friend. And they will be if the culture fosters and enables it. Too often they are just the unfortunate ones that end up detecting an error when its too late and delivering the bad news.
YOU CAN'T INSPECT IN QUALITY! It must be manufactured in.
Not intended to be a rant, but after 30 years in manufacturing I've seen very,very few companies that do this well. When done well profitability will increase. Good processes pay for the effort it took to develop them.
Once again, just my 2 bits