Back when zoom lenses were in their 'beginning' stages in the 70s or so, they were noticeably inferior when compared with prime lenses having only a single focal length. Part of the problem was that to keep the retail price of the lens 'affordable', a lot of compromises had to be made. Maybe cheaper glass, fewer coatings, etc. But for the average amateur that I was in the 70s (and still am), the results were more than satisfactory to my eyes. As I was shooting almost exclusively slides, even when projected on a 10 foot x 8 foot screen, the clarity was still good enough. But, when compared to images shot with my primes - my FD 135 f2 was my favorite - the clarity/IQ of the primes was visibly more 'crisp', using the same Ektachrome with the same ASA in the same camera. Not earth shaking better...but better. Back then, some of the third party manufacturers entered the market with some real low-priced junk, too. Unfortunately, some still believe that all zooms are optically inferior to primes based on the 'real world' of '70s photography. Zooms have come a long, long way since those early days. So have the third party manufacturers.
My favorite lens back then was the Canon FD35-70mm f/2.8-3.5 S.S.C. and used it for perhaps 75% of all my photography (mostly trains). I was never disappointed with the images taken with that lens. By todays' standards, it was a rather 'tame' 2x zoom. Today, 10x and beyond are commonplace. Not surprisingly, my most used, all-around lens today is the 24-105 f4 L and gets used for maybe 60-70% of my shots.
So, are zoom lenses today still optically inferior to primes? That's still true, but to a much lesser degree. Everything has improved in their design and manufacture. Slide rule calculations are now done to what? 10 places? On a computer. Automated lens grinding and coating ensure uniformity across all copies of a lens, and so on. So, all lenses have improved in the last 40 years or so.
But just as the lenses have improved, so have testing abilities and those abilities have been taken out of the lens makers factories and made available to everyone. But now, 'we the people' on the web have come to expect images sharper than our own eyes perceive them, even with glasses or contacts. 'We the people' expect that super-high quality for a less-than $500 price, too. Guess what, folks. Ain't gonna happen any time soon. Same reason my $20,000 7 year-old car, even when new, won't go 200mph at Indianapolis, either.
So, to actually MAKE lenses that retail for less than $500, especially zooms, a few compromises have to be made. Maybe the images aren't at their sharpest in the corners when zoomed out...or zoomed in. Maybe the lens coating isn't as super-duper as the high priced models have. And, quite obviously, the super special 'rare glass' is only used in platinum-priced lenses, not the budget lenses.
And yes, I think every lens manufacturer has produced more than a couple of 'duds' that just don't focus as perfectly as well as the rest of the pack, have a little more pin cushioning or barrel distortion than they should, etc. Somebody tried to save a nickel in manufacturing and produced a bunch of duds. Happens everywhere, not just lenses.
But, perhaps the biggest reason of all why I chose zoom lenses over primes in my 35mm film days and now in my digital days is that I can most often get the shot I want, framed like I want, without the necessity of having to change lenses. Even with Canon EF lenses, it's still a minute or so to put the front lens cap on, remove the lens, put the rear cap on, remove the hood and flip it over, put the lens in my bag, take out the next lens, remove the rear cap, put it on the camera, remove the front cap, install the hood, then aim, frame, and shoot. Meanwhile, "the perfect moment" just passed by 45 seconds ago! At one point 2 years ago, I had 5 zooms and 3 primes in my bag. So, for my shooting 'style', I was able to test what worked best for me. I've since reduced that to 3 zooms and 1 prime...the 135 f2 L. While the 135 produces super sharp photos, so do my other 3 lenses.
But as I have come to realize in the past 2 years or so, the small advantage in sharpness, or IQ, of primes over zooms is nearly gone. And even more so, neither my 'audience' - 90% 'me', and the other 10%, people who wouldn't know the difference, realize there IS a tiny-smidge IQ difference between one lens or another. They're happy with cell-phone shots! For what it's worth, I was perfectly content with the IQ an EF-S 18-135 f3.5-5.6 IS on a 30D produced 4 years ago. I think our perception of what is 'good enough' has, as a group of web-savvy photographers, become too 'perfectionist' for our own good.
Just one more thing. To minimize the time lost changing lenses, many prime photographers have two cameras. In my film days, I had two, frequently mounted on a T-bar mounted to my tripod, or on a double-camera strap around my neck. I've now opted for convenience and less hassle over laboratory-perfect image quality able to read the writing on a dime from 500 yards.