In most cases the retailer / manufacturer resolved the problems on the first attempt and thereafter I had no further issues.
This is the key. It costs considerably more to produce 100% flawless equipment vs 99% or 95%. As long as the dealer or manufacturer took care of the problem, it’s just an inconvenience you have to deal with. If they don’t, then we have a real problem.
The returned gear can be sold at a lower price to less discriminating buyers as B stock, blemished or whatever. As long as everyone is honest about the gear having cosmetic blemishes, it works out for everyone.