We use the BQ24702PWR for a long time with many many thousands with no issues at all. They are configured for a 2 cell 8.4V charging at 1.8A, using 12V for the incoming power.
Just now we are experiencing totally unexpected failure rate of about 15-25%, all of them put out about 2.5-3V with no battery present, expected 8.4V (idling). Replacing the chip takes care of the problem. By now we have about 20 bad chips. What should we look for? Could assembly house be at fault and if yes, what could it be? Faulty chips from the factory? Did anything change in the die, or any other process?