before we go too far down the road with the "plated shut via",
     i have a question that would help me distinguish the 
     problem/condition:
     
     is the via plated shut, or is it a matter of some of the via locations
     not being solder cleared completely through the HASL process?
     
     i am infinately familiar with the latter, but am somewhat surprised
     that the former would be requested by a PWB manufacturer...
     
     the latter condition doesn't represent a reliability problem based
     on my knowledge (yes, i am open to being educated! (-;), whereas
     i can understand each of the concerns raised with respect to a
     "plated shut" via.