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OMAP 3530 USB1 problem

I need help to resolve the issue with OMAP 3530 USB1 OTG port problem.

I have connected USB1 ULPI port to external ULPI transceiver USB 3326. I am operating this port in Host mode with Linux version 2.6.31

What I see is - the USB port works as expected on about 50% of the boards built so far. However, on the remaining boards, I fail to see anything happening when I plug-in USB stick. I tried different USB sticks. Occasionally I get message saying "failed to enumerate device..." . I am not sure if it a hardware problem. The problem doesn't go away even if I swap the PHY or processor.

Any help will be appreciated.