Thanks for your reply, Roger.
Why do you think it's so hard for New Sensor (and others) to make a consistently good and reliable tube?
In making tubes there are more chances to go wrong than right. There a lot of materials that can change from batch to batch. Wire gagues are not as precise as one might want, cathode coating consistancy is a big problem, having the micas really clean so they insulate well, getting the pins right (those vary a lot in diameter and the base of the tube is a purchased part).
When I visited the Sylvania plant in Altoona the man who have been running it for years told me they had 10 chemical engineers for every electrical engineer. Strange as it may seem, making tubes is very chemistry dependent. I was told that some years ago the Russians could not get cathode coating material from their usual domestic source. Getting it from the USA was too expensive so they got some from the Chinese. Turns out it wasn't so good for consistant emission.
I discovered this by checking emission and bias vs. filament voltage and found the tubes drifted all over the place and not together. Therefore pairs became rather unmatched as filament voltage varied even a little. I sent them all back. This is something we do at RAM TUBES that I can almost assure you no one else does. I personally do all the testing and because of my experience with tubes I catch these things that I presume others miss. I think a lot of what I send back ends up in some amplifier somewhere.
I recently looked at some other tube vendors who claim to sell very carefully and even custom matched tubes. They use the Amplitrex AT-1000 tester.
http://www.amplitrex.com/. This tester only tests one tube at a time. There is no way to equally warm and stabilize a test one at a time and get any reasonable number of them done in a day. Furthermore, it would be very difficult to vary filament voltage one tube at a time, record the data and compare it over a reasonable sample. You are not going to find out anything this way about the tubes you are dealing with today or the ones you get next month which will be different.
In my experience current production tubes get most things right but there are characteristics that certainly vary batch to batch. I wrote an article on this year ago, here it is. It also gives some technical reasons why people do hear differences in tubes. I do agree with the reader who states "a good tube is a good tube" My job is to find them, test them and pick out the really good ones
http://www.tubeaudiostore.com/whyamsochwhy.html