I'm not sure where you got all that from. I said bad pieces shouldn't be put in boxes to ship out in the 1st place.
As far as everything else discussed, it all goes back to stop putting faulty pieces in the boxes. No need to open up and reinspect things at all. Just do it right the 1st time.
I'm glad that Superman turned out good for so many but for the late shippers who might experience issues now and will get no replacements it comes down to the fact that someone decided to pass a piece that didn't turn out good. They looked right at it and passed it, or were temporarily blind to the problems, and now that's your situation. Same with Apocalypse, JSC Spidey or whatever else. All I'm saying is it shouldn't be as complicated as what you described...just stop passing faulty pieces and watch the overall complaints go down.
Of course there's breakage during shipping and then there's line wide discrepancies like Batpits, upside down arc reactors and sculpted/black wash application web lines vs painted on, but those are another can of worms.