I saw this come up in another discussion, and it seemed like it could support it's own discussion.
So, how are you keeping up with these ever tightening demands?
This is an issue many of us are facing today. Increasing quality expectations bring us to defect levels that are too low for reasonable sampling plans to detect and now we use 100% inspection and/or capturing failures on the line. The concept of an acceptable defect rate is becoming extinct. Unfortunately the processes that govern how we handle this have not kept up.