Rockwell test kind of thing?
I would ask the customer where he expects the test dimple to be, because there has to be one, and then ask him to specify that in any future purchase orders... what to do about the complaint becomes a business decision.
Agreed...but I haven't seen anywhere in this thread yet that states 100% inspection. (Maybe it's required, maybe not).
I would advocate having the discussion with the customer as to what they want...and where. Settle it out like people working well together, instead of in the middle of a returns process.
The results of the discussion should handle all the info you need for the returns process by default. Then, as Scott says, the actual part(s) in question become a one-time business decision.
I've seen a dummy plaque in heat treat with the parts, and testing done on the plaque so that the parts aren't affected.
Again, if 100% hardness test is required...that parts will have the dimple. Put it on the mutually agreed drawing in this case.