AMMO Does get produced in batches and are tracked by batch lots, to track things like this. It would be interesting know what came out of any batch lot reporting. @AmmoTech90 you are better at this than me if you want to weigh in...
Yep ammo is produced in lots, sometimes batched together. You are only allowed to use so many different component lots (say battery, booster, electronics) in a single overall lot. Sometimes it's one component lot, sometimes it's more depending on the exact item. The idea behind this is, if you can track the failure source down to a single component, only the full items that have the component need to be restricted/repaired/destroyed. This is also why there can be a mass restriction on all lots at first, until the problem is found. The risk assessment from the initial failure also has an impact on the initial action. A few more SAA misfires than normal on a weekend range, probably a local restriction on that lot and inform higher so other areas can be monitored. A grenade goes bang when the pin is pulled, all grenade training stops across the CAF. You have several premature detonations with 105 How HE and that entire model of fuze is restricted.
I guess what I was trying to ask and didn't do a good job of was, can you 'tell' by looking at the shells if there would be the potential that there was an issue with the proximately fuses or is the only way to know that there was an issue was to fire them?
You can look and, in the old days you could sometimes see. This was when prox fuzes had a liquid electrolyte that could leak. Most now are powered by a thermal battery with a solid electrolyte that is melted by a squib, or by a turbine. Obvious signs of corrosion would remove a specific item from service, and all similar items would be inspected to see if it is only a problem with that item, or the entire nature, or maybe the magazine is leaky.
In the CAF there are periodic inspections on all natures of ammo. A statistically significant sample is taken and inspected. Sometimes it is only visual, sometimes more invasive. Link ammo is tested to see that it flows smoothly. I've taken fuzes apart and checked the torque on internal fasteners (gets boring fast after the first 20). X-ray and high performance liquid chomatography is also used.
Proof is also a quality assurance tool that involves functioning the item in controlled, monitored conditions. For C4 we made little balls of a particular weight, conditioned them to various temperatures and then detonated them. Smoke grenades we timed the delay, timed the emission duration, and assessed the quality of the smoke. PETE Nicolet (used to?) proofs the big stuff as they have instrumented ranges. Often proof tests are carried out only when there is a problem as it is very expensive and the need for it can be reduced by good periodic inspections.