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Be aware and check the tolerance of the resistors. If the lot is running in the high end of a large tolerance, less current will be needed to reach the IC trip point.
Check the routing of the sense wires from the current path to the filter for the IC pins. The circuit will sense to the current path. If you have resistance on the board it will add to the effective sense resistance. Also consider the solder resistance.
Check your register settings for PROTECT3. Early data sheets has a typo in the reset value causing some users to set the reserved bit 3 to 1. This causes protection at a lower voltage (current). Reserved bits should not be set. Be sure to use the latest data sheet.
Also be aware of the tolerance on the current protection thresholds in the data sheet. OCSCALEERR may be 10% although not typical
