The timing is ironic that I am reading this with a print of one of our companies products on my desk. It seeem that we are on our 4th revision of a released product, Rev D in motion. In our case, it was due to design enhancements.
Though you bring up very valid points, they are issues that anything that is designed and engineered go thru. Take the whole Ford Explorer / Firestone ordeal. Talk about "When bad bugs happen to good"...products / people. I'm just glad that our CAD-package has not had any proplems to this level.