| That's why: "What does a factory reset entail?" is a fascinating question. Everyone assumes you'll lose your settings during a factory reset, but what isn't as clear cut: Does it revert the firmware to whatever it was shipped with (bugs and all)? Some vendors do, but most vendors do not. A legitimate factory reset (inc. firmware) mechanism or USB boot/reflash would have likely saved Samsung considerable amounts of money here (relative to mailing all of them two ways, they could have e.g. sent out free USB keys with the firmware). |
I think that's the only reasonable thing to do. Have the original firmware either as an actual rom, or only writable with an enable jumper flipped; use a power on key sequence to boot from the original firmware, copy to normal firmware and reboot into normal firmware (which is now the original firmware). Run through that process during manufacturing to confirm it works.
Regularly test that all released firmware images, especially those in the original firmware slot can successfully upgrade (or at least not crash). Preferably include current firmware version in all requests so you can give workaround responses as needed when you figure out you broke something -- in the hostname is ideal, as you can use that to work around version specific certificate issues.
The reason a Blu-Ray player (or a video game console) might not let you go back to original firmware is to prevent reverting to earlier firmwares that allowed copied media, etc. For those, you probably want to have a 'safe' firmware slot (or two, ideally) that drives the factory reset process, and only reflash those slots on some updates (to reduce testing needs)