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DM368 H.264 encoder performance variations

Our custom board based on DM368 displays performance variations doing 1080i H.264: approximately 50% of the boards cannot keep up with the frame rate, drop frames. When DM368 chips were swapped between 2 boards the problem followed the chip. I suspected PLL problems but TI confirmed my PLL settings were OK (http://e2e.ti.com/support/dsp/davinci_digital_media_processors/f/100/t/308115.aspx).

Had anyone seen the same or similar problem? 

TI support, do you have any ideas?

Thanks.