1) The math isn't a statistical analysis of a random sampling of lightweight revolvers equipped with the ILS. It's just a look into what "wear" means in the context of the article.
The math doesn't really tell us anything as its all based on complete conjecture. Neither you nor I knows for sure how many times Bane cycled the action of his revolver nor how many times he engaged/disengaged the lock. As such, conjecture about "wear" based on that incident is pretty meaningless.
2) Five minutes of research on the web will show hundreds or more anecdotal posts regarding ILS lock failures. Check the S&W Forum for their huge lock thread. The failure rate is likely closer to 0.0000091%.
Yes and those posts are nearly all anonymous forum posts which present numerous reliability issues. First and foremost, some people simply have an axe to grind with S&W and I wouldn't put it past a few of them to fabricate stories about the lock. Secondly, as I mentioned earlier, the knowledge level of an anonymous poster is not known and cannot be verified so, unless very detailed information is given, many "auto locks" may actually be caused by other issues but mistakenly blamed on the ILS. Finally, we have the internet echo chamber which skews the number of reports.
For those that don't understand it, here's a brief explanation of the internet echo chamber: Suppose we have three range buddies named Bill, John, and Tom. One day, while all three are at the range, Bill experiences an "auto lock" with his S&W revolver which John and Tom are witness to. After leaving the range, Bill posts about his experience on TFL, THR, and Glock Talk under three different handles, John posts about what he witnessed on the S&W forum, Colt forum, and Ruger forum also under three different handles, and Tom does likewise on Gun and Game, Warrior Talk, and Taurus Armed. Even if we assume that all three people are knowledgeable enough to diagnose a true ILS-induced lockup and all three are 100% honest about what they experienced/witnessed, one incident now appears to be nine. This and the other above-mentioned reasons are why anonymous internet posts are not a reliable indicator of the magnitude or frequency of an issue.
3) RE: Lightweight magnums: Bane has stated that repeatedly, not I. He says he can get the gun to do it on demand. I have no reason to doubt his credibility on the issue; he has far more to lose than I for saying it.
Do you have a link or other citation for Bane stating this? He stated in the link you provided previously that he intended to have the lock removed from all of his so-equipped S&W revolvers, so I don't really see how he could repeat the problem even if he wanted to.
The ILS opens the California market to S&W revolvers due to various silly laws there. It gives the parent corporation a client. It may or may not apply to the Clinton agreement (I thought that was gone).
Actually, it is Maryland rather than California which requires the lock. Also, Saf-T-Hammer no longer owns S&W and the ILS never met the requirements of the Clinton Agreement to begin with as that agreement specified a locking mechanism with a key unique to each individual firearm while the ILS keys will work on any so-equipped revolver (I've tried it myself).