Originally posted by BruceBanner Could be a QC issue then. I have no idea how it happens, I'm sure they are tested before going out, do they get injured during transport and thus some copies are a little misaligned by the time they end up in the hands of the consumer?
QA (different than QC) is sort of a strange game in that it is focused on process and sampling and not on final quality testing. As a result, final inspection is seldom thorough and a defined percentage of product will go out the door, technically "out of control" in one or more aspects. Rarely a product will be badly out-of-control. Whether the problem is severe enough to trigger a return or warranty service request depend on the purchaser and how demanding they are.
I will go out on a limb here and suggest that it would take a significant blow in transit to decenter a lens produced using modern manufacturing techniques and materials. After all, most of us never see a problem despite treating our camera gear no more carefully than we treat our lunch. Several of my lenses have been backpacked thousands of miles without special treatment other than the cases they came in. That said, given the resolution of today's sensors, many end users are in a better position to detect a decentered element than the final assembly inspectors. From reports on this site, it appears there is an epidemic of poorly aligned lenses, though I believe that the actual incidence is well within the QA targets set by the makers. I also suspect that the QA monitors are probably not sensitive enough and that a fairly large number of lenses with detectable decentering go out the door as OK.
The reason I say that is less rooted in user complaints of soft corners and more related to the high frequency of users seeking help with AF fine adjustment. One or more decentered elements along improper focus group adjustment are common causes of front/back focus in that such may cause the OOF image to AF sensor to be distorted and asymmetrical and ambiguous to the sensor.
Bottom line is that I am not too surprised by reports of someone getting two decentered lenses in two attempts to get a good one.
Steve