Rob,
I'm afraid I can't give you a answer to your specific issue (I doubt there
is a simple answer/reason), but I've been witness to similar issues
regarding board reliability in the past - the company I worked for spent a
lot of time & money trying to resolve the issues; some were down to board
design but in the main it was found that price was dictating the PCB shops
we used & they simply were not capable of producing defect free boards
consistently. In the end we put in place PCB design guidelines & a series
of PCB specification tests for bare boards that approved the PCB shop & the
material set. Cost for each qual was in the region of $5K. I hope this
response will be of some assistance & apologies if this response is low on
specifics regarding your query.
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