disappointing Hornady ammo
I haven't had your problem, but I was unexpectedly disappointed with some Hornady 40SW 180 grain TAP ammo I bought, not the cheap stuff. I bought it on the specific recommendation of the gun store guy who said it's what he used for defensive ammo. Ok, $25 for 20 I think it was, each round hand-inspected etc etc.
So I go to the range to test my 40SW handloads, some cheap WWB FMJ and HP ammo, and a few precious rounds of this Hornady stuff.
Coming out of a 3" barreled XD40sc, the Hornady was dissapointing. The 180HP from Walmart (Winchester White box) was consistent at about 880 fps, the Hornady a bit less. But one of the 5 Hornady TAP rounds I tested was a dud! Chrony'd that one at 550 fps (it felt and sounded different like a low-powered round,too), as opposed to the about 870 or so that all the rest did.
Maybe I had an extreme fluke, but I decided no more Hornady TAP. Better consistency and frankly quality with the WWB ammo and a lot cheaper. The Hornady TAP ammo just isn't worth the premium price, really imo it wouldn't be as good as the cheap stuff even if it were at the "cheap" price.