There was no epidemic of "plane knife fights" or "accidental pistol discharge in planes". Catching incidental weapons that weren't going to be used for harm is basically zero value.
All of the value comes from stopping people with bad intent from having weapons. If 95% of them can get through, then that's a very bad system.
In other words, I don't think you've correctly identified signal vs noise.
There was no epidemic of plane hijacking, either.
I have no data on the intent of people taking loaded firearms or black powder on planes (or knives in teddy bears,
Saying that 95% of people with bad intent can get through is unsupported by the statistic OP linked.
My point here is not that the TSA is great (I personally think it is pretty useless), but to suggest that single statistic is insufficient to demonstrate that the TSA is useless - you also need something indicating probably nothing bad would have happened had the TSA not confiscated all the currently banned stuff.
That's the system that was in place up until 9/11, and it was run by private airport security. The TSA was a response to that.
But it wasn't the only conceivable response. Changes to private security screening rules would have been another option. The TSA isn't just there in a vacuum. And if people who try to sneak items past it can succeed, then its mandate isn't very effective.
Part of why another 9/11 hasn't happened is that terrrorists know that people know that hijackings can be very deadly. So people wouldn't be so passive anymore. The 9/11 hijacking was done with box cutters. That feat couldn't be repeated again, even with box cutters on the plane.
https://www.vox.com/2016/3/29/11326472/hijacking-airplanes-e...
We only care about trying to take these things from people who are hiding them. Inconveniencing innocent travelers is a cost of the TSA, not a benefit.
I don't see how sane plays into it - either they are sane and accidentally have a gun in their bag, or they are insane. How can you filter by sanity?
Point is, probably most of the people with guns, swords, etc are not malicious, but I haven't seen any statistics on that, only this 95% cited over and over again.
I'd recommend reviewing the link though, as that number includes things you might not think are deliberate attempts to hide stuff (swords in canes?).
So while it is easy to beat, the TSA screens do succeed at enforcing the most obvious violations to current regulations. Whether the signal (things that seem like they reasonably should be confiscated) to noise (toothpaste, water, nail clippers, pocketknives) is acceptable, I don't know.