I just got my note 4 yesterday. When I was in the tmobile store they were switching over my sim ect so naturally it was opened at the store, when the rep gave me the device I inspected it, the champered edge on the top by the speaker speaker grill was cracked, it was really small but it was there. He had no idea what happened but they gave me a new one right on the spot. Samsung might not be as spot on with their manufacturing process as say apple.
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Any phone can have defects. Name any phone that is mass produced and you will find some that had issues with it. Quality Control is there to help prevent these issues but ... on devices mass produced like iPhone and Samsung products ... There is bound to be a few bad ones. The companies even know this .. That is why we have warranties .