My Warbot Defender had one of the shoulder struts attached incorrectly, making it incredibly difficult to move to the car mode position and has even cracked. Luckily, I recently reassembled it properly and the piece is so thick that I'm not too worried about it completely breaking. Also, the right knee and left outward shoulder joints are loose, but only at the first one or two points from a straight position. After that they're fine.

One of the worst QC issues with something official that I've encountered was with TM II Scourge. The chrome didn't chip or flake cutely, it almost literally molted off the damn thing. You touch it, and chunks of shiny orange flakes came off on your fingers. I finally threw the damn thing out, I couldn't stand it anymore.

To a slightly lesser extent, though only slightly because of the figure's cost, my Alternity Starscream's left door strut mounting piece is slightly up instead of straight out. The result is that the door panel pops off virtually every time one either gets it into the car mode position, or pushes it aside ever so slightly once in said position to get the roof assembly in/out. You don't notice that it has done so unless you look carefully through the windshield in car mode, or until you begin to move the door panel up and back.

I've also had to exchange a Recon Ironhide due to it missing the right arm cannon, but the replacement doesn't have anything really majorly wrong with it. Other than that, I've been pretty lucky.

 

My experience in nearly two decades of collecting has been a VERY positive one in terms of quality from Hasbro. There's the occasional paint applications that could be a bit better, but those things are very nit-picky to me, especially for the prices I pay for a product. I totally remember my experiences as a kid and having my favorite G1 toys break occasionally, but fast-forward to 2011/nearly 2012 - I'm pretty amazed by the quality and efficiency in regards to this issue.

 

Classics Universe Starscream's sloppy paint job. Batches of red on the limps. Red paint on his cheeks instead of eyes. Looks like he's blushing. Plus, one of the legs has disgusting looking barnacle-like gunk on it. And joints are very floppy.

 

most of my DOTM mechtech Toys have looses Arms joints/ball joints

 

The worst problem I've ever had was with HFTD Breacher, who had a peg that was too thick, so I must be really lucky. Oh, and my SWTF Chewbacca's lower leg broke off, but that's more of a design flaw than a QC issue.

 

My Animated Electrostatic Soundwave had two left lower leg pieces. Also got the Ironman crossover Jet a few years back as a gift and he had two right hands. Ordered Alternity Cliffjumper to find out he had no head.

 

My RTS Outback was missing a pistol when I opened him...

 

I had the same with my sentinel, I just put clear nail polish on it for a bit and now it's slightly better.

 

Was it because of BPS? (Brown Plastic Syndrome)? Quite a lot of SW Chewie's joints used that brittle swirly brown plastic that broke easily.

It was a bad choice of plastics. I returned several of them broken right out of the pack before just giving up. I do have a MOSC one for my collection but I have no intention of opening it because even in the unlikely event it's not broken already I doubt it would survive much transforming before ending up breaking too. If they'd just picked a less hard plastic to use for the sockets he'd have been a great toy.

 

RTS Wreck-Gar's Handlebars. Both of them broke off. UUUUGH.

~AAD

 

Like atleast 3 Generations Thundercrakcers all with Floppy Wings that look like they may break.

My Universe Sideswipe has red paint all over windshield.

Stress Marks on most fists (though that's my fault because i'm really clumsy) but my DOTM Skyhammer had a stress marks on a bit of plastic.

Stress Mark on TFA Sentinel Prime's head and RTS Wreck-Gar's Ball joints.

 

-twinkle eyes- I'm not alone!!!

 

I forgot about that. That's a pure QC issue that goes beyond just an error or minor issue.

I read 2 huge threads about the problem when I finally got mine, followed advice on how to transform him and still got a tiny crack. It still took a lot of force to transform that leg.

Recently found a second and clipped the handlebar nubs immediately. I may just leave one in each mode. Hopefully Junkheap turns out okay.

 

The Wreck-Gar handlebar breakage isn't even a QC issue. It's a design issue. If you don't fix it you're almost guaranteed it will eventually break.

 

The toys with heavy GPS problems. (Namely G2 skyquake)

 

i chose these either because of the price, or the amount of time it took me to find the toy to begin with.
-MP Greenscream - stressmarks. Fingers also like to come off.
-One of my RTS Wreckgars came without the axe weapon.
20th Anniversary Prime has a knee joint that sometimes fails to lock, thigh sometimes collapses into the leg.
Hasbro MP Rodimus - paint scratches. visor stays up, but also sorta falls down instead of letting me position it where i want it. no happy medium.

 

I'm not sure if this counts as quality control but the worst I've had is this:

 

Well, technically, none of this is "quality control". It's quality control PROBLEMS. I.e. things that slipped through DESPITE quality control. "Quality control" just became a shorthand for fans who now use it in a way that conveys the opposite meaning. (Also, your case is specifically a case of misassembly.)

 

This thing:

 

What about it?