This is actually a perfectly clear and spot on idea
There have been good viewpoints on both sides, plus for example, MidWay is in no way inspecting these guns. All of mine are in the factory plastic bag with oil all over them, rubber banded up. MidWay is not paying employees to function test and inspect thousands of cap and ball revolvers plus paying people who know what to look for would be expensive.
The average buyer of a Pietta brasser is rarely going to shoot it, and Pietta knows this. Some of us do, I love a good Brasser but I remember these things when they were 79 bucks at Gander Mountain circa 2001 or so, and people bought them as woods blasters and to let kids run around snapping caps on them. There's probably tens of thousands of them quietly rusting away wrapped in old t-shirts in basements and garages across America. They're still 220 bucks, most buyers want to stuff it full of Pyrodex and if it goes Boom, life is good. They will still function safely with the chamber out of alignment. I'm sure half of my Piettas are like that.
Part of that theory makes my head sad, picturing a hard working Dad buying a blister pack .44 Navy to teach his son about Civil War Guns and dude gets a lemon that has an action that's like 20 miles of bad road, shoots 2 feet left and binds up after 3 shots because the hand isn't fitted right. But that's just Capitalism. Pietta sells the Grade C guns to people who probably won't care.
If the retailer has a return policy like Dixie, I assume they ship returned , defective guns back to Pietta for "credit" or for new guns. So Pietta doesn't want containers full of returns, so they make sure Dixie gets mostly good guns. The reviews show some lemons but they probably put some guns with sketchy QC in there too.
Or we are all wrong and Pietta and Uberti just make guns with varying levels of fitting, some good, some by the new guy, some were fitted at 4pm on a Friday, some by an older guy who makes more $$ and tries harder, and you get what you get.
The "cleanup" gun theory is solid, they go through the parts that got messed up and just use them, and blend them in with other guns if they need a few more guns to fill an order.
It's apparently a myth that Cimarron gets a "better" gun, they do have their name stamped on them so you'd think they wouldn't want turds with their brand on it but again, who knows. There are reports of bad Colt 2nd Gens too so you just never know.