Wait, people actually did that back then?

Oh man are we really acting like this is some huge problem? I've been using PDR tools for years and never had clear coat crack like that. Sounds like you're blaming the tool when it was probably your technique or that dent was already compromised. Cold paint can be tricky but you gotta work it slower and let the metal relax between pushes. I've seen guys go ham on a dent thinking pressure fixes everything when really it's about finesse. Plus a tiny tip doesn't automatically mean disaster you just have to support the surrounding area better. Maybe test your methods on scrap panels before jumping into customer work.

Ha, guess my cheap earbuds weren't made for fighter jets. Go figure.

Look it's not like i'm defending the contractor or anything lol but is 1 out of 20 really that huge of a deal? That's a 95% pass rate which is pretty solid for a first pass on complex military wiring. Plus the automated stuff catches the big obvious problems way faster than a human can. The real issue is probably just them not giving the techs enough time to do a thorough manual check before it ships out. If the manual guys are catching it before the harness goes on a plane, then the system is working exactly as designed.

Ericfox nailed it. Just kick the meeting to next week.