Good points.
Anytime you have rotating mass you introduce the potential of some level of vibration since there must be tolerances in the fitting of components. Engineers understand this and in the design phase they incorporate methods to control (hopefully) all the variables that may impact it. Some of that is balancing, some of that could be dampening.
In the case of Road Force balancing the generally acceptable maximum down force is around 20-25 pounds. Obviously zero is the desired amount, but when dealing with production tires and wheels, zero is likely to be an impractical number. To the best of my knowledge the newer Road Force machines do a preliminary lateral and radial runout check before the tire is placed into it's final position. If the wheel runout is excessive, it's possible that a tire could also be out of specification enough to offset wheel runout and hit an acceptable downforce. The problem, however, can or will show up the next time another tire is mounted on that wheel. Then again, I would bet there's a small population of technicians that either do not perform the operation correctly, or will accept out-of-spec because of time.
Companies do manage warranty expenditures, however there is always a threshold of pain, both for the customer and the reputation of the company that is usually considered. In many cases a resolution is known but for various reasons the supplier cannot ship good parts at the level needed.
Then of course there's the dealer's service staff. Some may be competency issues, some may be workflow or morale issues , some may be a lack of customer empathy.
Regards,
Dusty
2019 Ram 1500 Billet Silver Laramie Quad Cab 2WD, 5.7 Hemi, 8HP75, 3.21 axle, 33 gallon fuel tank, factory dual exhaust, 18” wheels. Build date: 03 June 2018. Now at: 044780 miles.
