App loads but doesn't start

[jtm214]

Hi,
I have about 70 custom boards using the ESP32-WROVER-E (16MB) module and I've run across 7 of them that will not run an application. The devices are programmed with a ESP-Prog programmer using idf.py flash monitor in esp-idf 4.1. The majority of the devices work just fine programming the factory partition, enabling secure boot, etc and moving on to OTA updates. Though these 7 will not run the application and just hangs (by hangs I mean there is nothing on the monitor output). I've tried loading the hello_world example just to verify it wasn't my application and it does not produce any output.

As far as hardware things I've tried:
- Adding capacitor on the EN pin
- Verify bootstrapping pins
- Verify power source
- reflowing the module

I'm at a loss of what to do next other than swap the module out entirely but the 10% drop out rate isn't going to cut it moving forward.

Here's an example log from the monitor for the hello world example:
[Codebox]dev@ubuntu:~/esp/esp-idf/examples/get-started/hello_world$ idf.py flash monitor
Adding "flash"'s dependency "all" to list of commands with default set of options.
Executing action: all (aliases: build)
Running ninja in directory /home/dev/esp/esp-idf/examples/get-started/hello_world/build
Executing "ninja all"...
[1/4] cd /home/dev/esp/esp-idf/examples/get-starte...*************************************************"
Partition table binary generated. Contents:
*******************************************************************************
# Espressif ESP32 Partition Table
# Name, Type, SubType, Offset, Size, Flags
nvs,data,nvs,0x9000,24K,
phy_init,data,phy,0xf000,4K,
factory,app,factory,0x10000,1M,
*******************************************************************************
[2/4] Performing build step for 'bootloader'
ninja: no work to do.
Executing action: flash
Choosing default port b'/dev/ttyUSB1' (use '-p PORT' option to set a specific serial port)
Running esptool.py in directory /home/dev/esp/esp-idf/examples/get-started/hello_world/build
Executing "/home/dev/.espressif/python_env/idf4.1_py3.8_env/bin/python /home/dev/esp/esp-idf/components/esptool_py/esptool/esptool.py -p /dev/ttyUSB1 -b 460800 --before default_reset --after hard_reset --chip esp32 write_flash @flash_project_args"...
esptool.py -p /dev/ttyUSB1 -b 460800 --before default_reset --after hard_reset --chip esp32 write_flash --flash_mode dio --flash_freq 40m --flash_size 2MB 0x8000 partition_table/partition-table.bin 0x1000 bootloader/bootloader.bin 0x10000 hello-world.bin
esptool.py v2.9-dev
Serial port /dev/ttyUSB1
Connecting........__
Chip is ESP32D0WDQ5 (revision 3)
Features: WiFi, BT, Dual Core, 240MHz, VRef calibration in efuse, Coding Scheme None
Crystal is 40MHz
MAC: fc:f5:c4:3c:f6:18
Uploading stub...
Running stub...
Stub running...
Changing baud rate to 460800
Changed.
Configuring flash size...
Compressed 3072 bytes to 103...
Wrote 3072 bytes (103 compressed) at 0x00008000 in 0.0 seconds (effective 1540.7 kbit/s)...
Hash of data verified.
Compressed 23984 bytes to 14886...
Wrote 23984 bytes (14886 compressed) at 0x00001000 in 0.3 seconds (effective 569.7 kbit/s)...
Hash of data verified.
Compressed 147360 bytes to 77579...
Wrote 147360 bytes (77579 compressed) at 0x00010000 in 1.8 seconds (effective 651.0 kbit/s)...
Hash of data verified.

Leaving...
Hard resetting via RTS pin...
Executing action: monitor
Running idf_monitor in directory /home/dev/esp/esp-idf/examples/get-started/hello_world
Executing "/home/dev/.espressif/python_env/idf4.1_py3.8_env/bin/python /home/dev/esp/esp-idf/tools/idf_monitor.py -p /dev/ttyUSB1 -b 115200 --toolchain-prefix xtensa-esp32-elf- /home/dev/esp/esp-idf/examples/get-started/hello_world/build/hello-world.elf -m '/home/dev/.espressif/python_env/idf4.1_py3.8_env/bin/python' '/home/dev/esp/esp-idf/tools/idf.py'"...
--- idf_monitor on /dev/ttyUSB1 115200 ---
--- Quit: Ctrl+] | Menu: Ctrl+T | Help: Ctrl+T followed by Ctrl+H ---
[/Codebox]

Any suggestions would be greatly appreciated.