the problem is in testing and just how statistically unfeasible it is. case in point, we had a line that passed every QA test but we would still get back 1 product every now and then from a customer with spoilage. we'd test thousands of samples each year and they're all fine but still something was the problem. on top of that, we had "nearly identical" lines that never had any problem.
luckily we found the problem in the line and how to push the failures alway the way down to zero for little cost instead of corporate wanting to pay $10 million to fix it.
so no, corporate isn't some boogy man.