I have to say that that is something which seems to have improved a lot in recent years. It used to be that one had to remove at least some of the case to replace many of the 'likely to fail' components but that is, at least in terms of machines I've got/had, generally no longer the case.
We have had one duff washing machine out of the half dozen or so we have had. Can't remember exactly what happened now, but it worked out of the packing, and then after a couple of washes didn't. The guy who picked it up said they were rubbish and he was always picking them up for replacement / refund. And also that the broken one was going to the tip. We weren't impressed with that brand, (can't remember but it'd have been a "decent" make.) so bought another from elsewhere on offer.
Examining early post-sale failures should be part of the overall QA process, shouldn't it? The WM of mine that just would not do anything when it arrived presumably will have been subjected to at least some sort of testing prior to leaving the factory, so the fault presumably arose during distribution/delivery (maybe due to some 'loose connection'!).
Maybe not, in the cases you're talking about, but I'm sure that such examinations have been known to reveal design or manufacturing (and maybe even packaging or distribution) problems, the addressing of which would save the manufacturer a lot of money in the long term.
Or maybe their QA etc is good, and a failure is so unexpected, that they want to know what happened.
A company I once worked for had a customer who was aggrieved that his servers didn't ship when promised. Somebody (not I), thinking on his feet, (at the same time as putting both of them in his mouth and shooting them) said it was because we'd carried out extra checks at the distributor's premises to ensure 0% problems on arrival.
It's been repeated by so many people in so many different fields, that the origin is probably impossible to determine, but I think it was the CEO of Pan-Am at the start of the passenger jet age who first said "If you think safety is expensive, try having an accident".
I have similar story. A few years ago, the engine of a Mercedes of a friend of mine 'blew up' (almost literally). It was an expensive model which he had had from new, but was well out of warranty (I think 6 or so years old) and had done a considerable mileage. When the local dealer reported this to the manufacturer, their response was "Mercedes engines should be good for at least 250,000km, no matter what their age" - and replaced the engine FOC and, as in your example, took the old engine away, presumably to examine it.
It's true that the OP has not answered that specific question, but he has indicated that the socket 'works' (without tripping) with a small load (his phone charger) and, more importantly, that the RCD does operate if he plugs in the DW and switches on the socket with the DW itself switched off (hence representing little or no load). That almost suggests that the is a fault in the DW's flex (or within a moulded plug), rather than that the problem is related to their being a fairly large load (such as a kettle) on the socket.
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