I worked in product safety testing, specifically designing testing programs for McDonald Happy Meal toys.
The tests for toys intended for children under 3 years old are clear. There is a bite test, a drop test, flammability tests, pull tests, etc. If paints are used, you test for heavy metals in paints.
Lead happens in domestic paints as well. The allowable limit is very, very low.
McDonald’s has all its toys made in Asia for the last two decades. Statistical sampling and testing of the toys as they are being produced reveals any possible flaws before the toys leave the factory. The testing only takes a day or two.
It is clear to me that either Mattel did not randomly sample the toys properly to establish their safety or Mattel did not test the toys at all until they arrived in the United States.
Either way, Mattel took the cheap route and is now paying the price via their reputation.
McDonald’s was committed to never, ever having a Happy Meal Toy recalled for a clear safety defect.
Interesting. Thanks for the inside perspective. I've had some exposure to product liability issues with a manufacturing company. It's paranoia versus common sense, and paranoia often wins out.