It’s more when the part numbers cannot be verified or the parts haven’t been removed yet to get measurements etc. We actively offered the option of taking all the options and returning the unused bits to save any downtime and wrong parts being delivered.
It wasn’t always as simple as following the books/systems unfortunately as I’m sure you know yourself, factories threw whatever they could into some cars, people have modified them etc. etc.
I am going to contradict myself hear and say I agree with you. The returns process inside our place is absolutely mad with protocols and paper work and its very off putting
Even with the right tools in place we still manage to send out wrong parts on a daily basis.