Didn't remark on all the parts John. Just one. Do not represent me as having commented on anything but one. That's crass, and you know better.
That's a nice opinion that "nobody designs like that". It's also a nice opinion that I don't know what I'm talking about. There are acceptable design standards that are followed, based on precedent by making similar parts over the years, industry-wide. Over-designed those handles ain't. They were made to a design standard that said that x+Y= good enough and it saves z dollars over a more robust one which is deemed unnecessary. All driven by up-front cost. Have a great weekend.
No, you didn't remark on any other parts, but those parts are still there, and each one has the potential to have the same sort of problem. You can't apply a unique standard to one part unless you have the benefit of hindsight, which of course all second-guessers do. I'm not sure how that would be stupid or insensitive, but I'll give you your opinion.
Yes, those are very nice opinions. They are mine and I like them. And you are very correct that acceptable design standards say that you review all designs to see where there is excess and waste, and you work to correct those deficiencies. You also work the other way and look to see where designs may be questionable or inadequate so that you can correct the other way. And when dealing with a consumer product, up-front cost is a pretty critical thing to be aware of, since getting it wrong will put you out of business just as fast, and maybe even faster, than quality problems will.
I have noticed that this "crummy thing" does not experience universal failure, suggesting that it may not be quite as bad as some think. I have 190k cumulative miles on two cars with intact door handles, and I know of quite a few others as well. So maybe the design is perfectly adequate until manufacturing variances are taken into account. If the process is less consistent than first thought, a strengthening of the design would compensate for those parts made at the low end of the tolerance range.
And thank you, I will have a nice weekend, assuming that the weather man is on the high end of the tolerance with his forecast.