GambitRSA,
Hang in there and don't loose faith. It can be extremely frustrating and most of us have gone through more than one exchange. Some so many that it's difficult to believe.
Nonetheless, we end up finding a phone that meets our own standards. Here are thoughts that I noticed during my experience:
1. After being affected personally with this a defective phone and reading daily about others having the same experience, I became extremely sensitive about defects. I began looking for and noticing imperfections that would never have hit my radar had I not been so in tuned with this problem. Each of us have difference levels of standards, so go with yours. For me it helped to take a step back and do a reality check. I soon caught myself that I was overly sensitive. I'm not saying by any means to accept a defective phone, but just that nothing is perfect. If you look for defects, you will always find them. I think some on this board have caught this "bug" as I had. It's understandable. So, just remember to don't loose your mind over the little stuff.
2. While we would all like to hear Apple go public on this, IMO it will never happen. It can't. Doing so would result in a forced recall and damage the image of the iPhone and Apple. As it is now, the only damage is among a few people that are really affected by this. Boards like this help us vent. If Apple were to come out publically, this would give a license to every dishonest customer to demand refunds and compensations. Especially with the phone being sensitive to scratches, there would be no way for Apple to determine which were defects and which were caused after by consumers. So, Apple can't and will not address this publically.
3. Rather than addressing this publically, I believe Apple is doing what they should and makes the most impact to us. From the news it appears they are addressing production issues at the source in China. Hopefully these efforts will have better quality levels which will soon be noticed by consumers. So hopefully the guys on here opening up tons of boxes won't have to do that soon.
4. As far as customer service goes, unfortuantely mileage will vary. My experience was nothing short of excellent. Both via phone and in store. But I have read horror experiences by others. All I would say to this is that you should find the right people at Apple to help you. If you get a sassy attitude, don't accept that and escallate to speak to a manager. If the Manager is not helpful, call in to Apple HQ and report the experience. There are people that are aware of this and are helping, so don't loose faith. Just find reach out to Apple and find an advocate. I'd recommend calling in for this.
While I can't say if the production quality will get better, I would find it difficult to believe that it won't knowing that Apple is addressing the issues with Foxconn.
Keep the faith and good luck in your exchange.