Does anyone see their Mascot system going out of sequence random

We run Mascots for leaded assembly on 15 stations for 20 product types in around 2500 variations...the system works brillianlty for us, but we experience programs going out of sequence for no apparent reason spontaneously - literally, an operator can build 73 of a unit, and the 74th time the program is run the build order is all wrong. We have profiling enable for most of our programs, but both profiled and non-profiled programs can drop out of sequence. The issue is always resolved through updating the kitting files. Any ideas?

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