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TPS562201 failing on some prototype PCBs with permanent in-IC SW-GND short

Other Parts Discussed in Thread: TPS562201

Hello,

Strange problem here with the TPS562201: on some boards, on first power-on, it makes an audible noise, draws around 200mA (whereas load needs only 40mA), and then results in pins 1&2 (SW and GND) shorting (confirmed with multimeter continuity test on unsoldered chip). 

Replacing the chip on a problematic board results in the same experience However the same exact design on other instances of this PCB works just fine.

These are hand-assembled prototype PCBs; the caps/resistors/inductor do look fine from a visual/microscope inspection. There is no output short on the problematic boards without the chip or when a fresh chip is installed.

Circuit below. It's a somewhat bizarre problem which may simply be due to hand soldering problems, but I would like to at least have a rough idea of what may cause it. 

Thank you in advance for any ideas/suggestions!

-sergei