I can shed some light on Revell's policy....
My son got the big 1/96 scale USS Constitution kit back in early August. When we looked closely at the kit, we discovered that the bag of black sprues was missing. The kit is molded in three colors- black, tan, and white. All the sprues of each color are packed in together in a plastic bag, and we were missing the bag of black sprues. We were missing a couple hundred parts- all the cannons, eyebolts, yards, deadeyes, anchors, etc.
I went to Revell's website, and found that all you can do there is request up to 10 parts, by part number, for $3. So, I wrote a letter explaining our problem, and sent it. About 3 weeks later, I got a reply from Revell. We got an envelope with a copy of my original letter and a photocopy of the webpage showing the "how to request replacement parts, 10 parts max" policy.
I was not pleased, and sent a second letter, expressign my severe displeasure. about 3 more weeks went by, and then I got a call from someone from Revell. He apologized, and told me the following:
Revell uses a "Fulfillment House" to handle the parts requests. He said that it is more efficient to have the parts separated into bins, off the sprues. Most of the requests they get are for a single part from one of the kits with relatively few parts. (Think car kits.) The people at the fulfillment house don't know anythign about models-- all they know is they have a number bins with parts from kit 1234, and all they do is find part 34 and mail it.
He also told me that they had the limit of 10 parts because they felt that unscrupulous people had taken advantage of them to get kits for free- again, based on the fact that many kits don't have that many parts.
He said that he realized that the big Constitution kit was an exception, and that they would open up a kit and send us the bag of black parts. He said that the fulfiullment people only have the bins of parts, so they have no idea what parts come from what sprues, or how many would have come from the bag.
He ended the call by apologizing again, and told me our parts sould be sent. That was 3 weeks ago-- I don't have them yet- I expect them soon, though, or he's going to get a call back!
I should have taken the opportunity to complain about their $3 charge for replacement parts. Why shoudl I have to pay extra because they screwed up? I Bought a 1/72 tank kit that was missing the decal sheet- I wasn't going to pay $3 to get a replacement decal sheet for a $9 kit! IN my eyes, that is rewarding them for bad beahviour-- bad quality control is rewarded with my paying an extra 30%!!!!
-Bill