TPS2124: Output fails with 1A Load (IN2, 5V)

Tool/software:

Good Afternoon.

I am using TPS2124 to switch between 12V and 5V for a power output, controlled by SEL from a GPIO.

My design is required to provide 1A through TPS2124, (tested with an electronic load). When the electronic load is turned on at 1A when set to 12V, it works fine, but on some of my boards (20%), when set to 5V, the TPS2124 fails to provide an output when 1A load is turned on. It works at a 0.9A, and can provide 1A if the load is gradually increased.

Output goes through TPS16530RGER eFuse before the output power connector.

Any insight to why this may be happening? I have run out of ideas and my current theory is either faulty IC or an assembly error.

Attached images show the schematic and the output.

Thanks!

Tom