Kahr took over AO in 1999 and the general consensus is that they have made improvements. Given that, there's enough remaining negative feedback that it's old, bad reputation is slow to end.
Of all the cons I've heard about the AO, the supplied magazine seams to be the center of most issues. The unanimity is that they're junk!
The second complaint that may contribute to your customer's problem is that a significant number of AO's require some extractor tuning. (Typical of unmodified ejection port 1911s.)
Does the owner's manual really require the owner to "...use only ball (FMJ) ammo..."?