No one ever looked at where the root cause of these discrepancies was in the production of the product. That seems pretty basic. It is common thinking, especially in manufacturing environments, that you can't afford production down time. It takes people who are empowered to say 'stop the presses' to truly find the root cause of some of these issues. But usually, everybody is in constant activity mode doing something they believe management expects them to do.
Management thus gets what it works toward.
If management wanted it any other way, people feel, they would have done something about it. But senior management is often too busy or removed to see issues as they arise. Implementation is also a concern. Organizations also fail to assure that what a product wants is what the process does to it, when attempting to bring about the It has be desired outputs. A fact, man process management thinking, I find, is lacking in most operations and managers.