Your point about cost is the reason I talked about culture. It is easy to throw money at things but what we are looking for is an improvement in quality at low or zero cost by making everyone in the supply chain aware that quality matters.
The product designer will identify a number of different solutions to a given task (such as electrical connections between engine and tender). To what extent does he make his choice based upon quality, reliability and maintainability? The same considerations may apply during process (including tooling) design: for example can a process be made self-checking? The product may cost no more by including features preventing faulty assembly, for example, but these features will only be included if quality forms part of the design mind set.
Many years ago during my student apprenticeship, I was told my a machine operator that it was his job to make things. It was somebody else's job to check whether they were correct or not. Let us hope that the inspector detected any faulty components, in which case the costs were those of her wages and of the scrap involved. But inspection doubles the manpower requirement and may not work - inspectors see what they expect to see. So the fault may not have come to light until assembly (stopping the process) or by the customer during installation or in-service failure. All additional costs incurred because the operator did not think he was responsible for the quality of his work.
Is there not a parallel with our Chinese-produced models? Have the operators, assembly and packing operators been trained to believe that quality matters and that, if they see something that doesn't look quite right, they should flag it up? Or is quality not part of the culture in which they work; their customer will expect and allow for quality problems, which will be identified by the end-user on the other side of the world. I wonder which approach actually costs more?
The quality and reliability of other consumer products has improved dramatically over the last fifty years. In simple terms, I would suggest that the main reason is that consumer pressure has forced suppliers to address quality throughout their organisations. Costs may have increased somewhat but I don't think the costs of manufacture have rocketed.
Maybe we should be asking our favourite manufacturers about their approach to quality, and telling them that is as important as, for example, choice of prototype.