This thread has only just been drawn to my attention (and not by any one of the posters showing their chips).
Firstly I have to point out that at no time ever since we opened has any customer contacted me about this.
I'll try and explain why it can happen, and I've asked the factory manager to conduct some tests for me tomorrow which I will report back on.
The chip edges are finished with a grinder, not a lathe. It is a 'centerless' grinder comprising two large wheels slowly moved towards each other with the chips inbetween. Occasionally, for whatever reason (tiny foreign object getting lodged between etc.) a wheel can get damaged or worn in one place or other. This may affect the odd chip and I'll explain below why this isn't always noticeable in QC. We ourselves became aware there was some wear around a month ago and simply avoided that part of the wheel until it comes to a point where the wheels have to be 'dressed' (ie ground against each other very carefully!! to remove any blemishes). We were only aware of an occasional chip with such an issue, and thought the extras provided would cover any we had missed.
This grinding is done at ultra high speed and chips will flex by a few thou here and there during it as they get hot also, hence very occasional issues will arise and may miss QC.
The chips are inspected pretty much as soon as they are ground and shipped pretty much straight away. Once they are ground there is no 'going back' so to speak and we don't want them standing around in the factory for any period of time where they may be subject to extremes of temperature hence as stated we grind, inspect, ship in short order.
That does not mean the QC process is not thorough or is flawed. One thing most people will be aware of from looking at any of our chips is that the center point of the edge of any chip is invariably a fraction darker when the chips are delivered. You've seen pics in this thread showing how the chips look when they come out of the mold so it's understandable there is more to be ground off from the center than the edges. Consequently they get a bit hotter at that point. Playing, shuffling, handling the chips gets rid of that 'center line' pretty quickly.
What I see in the pics I have looked at is that these 'speed bumps' are far more noticeable when chips have been oiled. In fact looking at pics here of stacks it seems that many of the flaws are just the oiling making that darker center line more prominent and are not actually raised points at all. Again that will disappear with a bit of use, so I'd suggest that the majority of those posting who have not noticed anything amiss have either used the chips enough that nothing has noticeable, or they didn't oil them. This explains why the issue has not been picked up during QC.
If anyone has a major issue with a large part of their set then theoretically they could be re-ground just a fraction but I find it strange that this has never been mentioned before by anyone. More than an occasional flaw is not deemed acceptable and obviously could have been rectified if pointed out and proven at the time.
As I said, I've asked for a couple of tests to be done and photos sent to me tomorrow and then I will report back again.