The plan says inspect five pieces. All five pass. Piece ninety, pulled because it looked different, fails a diameter. The other one hundred and ninety are already packed. The failed one was from the end of the bar.
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Five pieces do not bless a lot if you already found a bad one. The end of the bar is a known place for size to move. Unpack enough of the end-of-bar parts to see if ninety was alone.
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Change the sample to include the start and the end of a bar, not five convenient parts from the top of the tray.
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A packed lot is not a shipped lot if you know about piece ninety. Stop it while it is still in the building.
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