The quality control of Cold Steel probably is more consitent, but the problem is they've never understood the requirements of this type of blade to begin with. Their blades are full-hardened, and as such are brittle when subjected to the force of blows that their size and weight can generate. I've had two of the Ghurka Khukuries, which is their heavy model. The first came to me with a loose handle and was returned. The second developed a loose handle after a couple months of use, and the front 3/4" of the blade broke off when I accidentally caught a higher branch that the one I was cutting. True, since it wasn't the one I was swinging at, the impact was a not perfectly lined up with the edge (kind of a hard glancing hit) but that doesn't change the fact that the overall khuk was too hard. There's a reason even high quality axes aren't hardened up to 60RC. Thin steel is too brittle at that hardness for such massively heavy impacts.
HI khuks are differentially tempered to be hard at the sweet spot, and softer at the point and spine to absorb the shock of heavy use. It's true that there is some variance in the size of the hardened area (etching similar models will show differences of an inch or so in the lengths of the tempered edge) but problems are very rare--In over twenty HI products I've received there's been one problem, and it was replaced within a week. This is probably the most telling thing, that HI is backed by unconditional replacement guarantee if broken in use. This last is something that Cold Steel won't match. I know this for a fact, because their response to my loose handle on the second one after use was "We can only replace items due to factory defect. These are tools and nothing lasts forever." This after two months of use on small trees and brush is inexcuseable for a $100+ knife that's supposedly built to be tough.