I've had new plugs bad out of the box twice in my life. Once in a Karmann Ghia and the next in a Datsun 200SX. Plugs were handled carefully, not dropped, etc. Both were Champions. Since then, I'll use anything but Champions. Never had an issue with AC, Autolite, Bosch or NGK. Never did try to take one apart to see why it failed to work. Seems to me all it could be is an open between the electrode and the top (where the lead snaps on).