Malletizing procedure... I've got to remember that one! Gives me an image of technicians with mallets chasing around a bunch of bushamsters! Kinda like WackaMole...
Sorry, couldn't help myself.
Sniper03, thank you for that detailed information. If that kind of crap happens to LE shipments then no wonder civilians get problem guns too. Only thing is so many slap on a RDS and don't see the alignment problem until later.
You don't have to say who the second manufacturer is but I suspect ArmaLite, DPMS or Bushmaster since they routinely use the A2 height FSP on flat tops instead of F-marked FSBs. I had to buy a Bushmaster taller front sight post for my ArmaLite to solve the problem of the factory front sight unscrewed enough to wobble around when zeroed at 50 yards. A lot of people don't know they have that problem until they replace their commercial height rear sight with a standard height model.
Sad that some manufacturers ironed out these problems long ago yet too many companies follow along blindly, even making the same mistakes or not using quality assemblers.
Quick fixes that one LE dealer routinely performs on Bushmasters: http://www.m4carbine.net/showthread.php?t=13532
I imagine he'd send back barrels that need reindexing.