Suspect you may have hit the nail on the head
Hi Tony
Agree that batch size may play a major part in consistency. Over the years I've noticed that paint mixed in gallons is more likely to match than pints even when mixed by the same person.
But having said that there is another really key issue the word "MIXED" probably to many of us take too little time mixing / stirring paint. Once we have taken any paint from a can that is not really mixed all hope of the paint matching is pretty much over.
Also different colors are easier to get good match like light stone is easier than olive drab. Just as some paint will fade quicker.
Cheers Phil
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