Would it be costly to try these different approaches (disable MTP,
alternative flash) to help narrow down the root cause? Could we pull
out a few devices and let them spin testing these options repeatedly?

When these things do wedge, do we get any debugging information? Note
that if we built that headphone cable I mentioned over the weekend,
we'd get a serial console.

Thanks for summarising the problem and offering some good suggestions
for next steps.

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