A tiny length change can ruin a light splitter
A splitter must divide light 50/50. Our simulations showed that the splitter length carried over from an earlier design would have sent about 93% (simulated) of the light one way instead of half. We caught it on the computer, not in the cleanroom.
The chip now also carries a small grid of splitter variants, so the first run pins down the exact value for every later chip.