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The biggest problem with mass-produced electronics in general is that you produce so many, it becomes difficult to have every device inspected and at the same time keep the device cheap for your customers. Things like bad batches happen because of the random sampling process manufacturers use. It also means that some percentage of bad units will get through to the public. What little numbers I've found is that ~1% is actually average.
And I know some folks will ask for a new replacement unit for anything defective, not liking the option of a refurb. But really, your odds of getting a good unit are better with refurbs, since they all get inspected before they are sold or used as replacements in warranty work.
And it's completely possible to get two bad units in a row if they are both new. The odds of it happening are the highest in this scenario. What sucks is if customer service is a problem when it does happen (and the odds are always non-zero, if small, so it will happen).
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