One of the biggest tricks to making a flint lock work well is for the frizzen to be able to flip out of the way easily. If there is a rough spot on the spring or the point where the frizzen rubs on that spring it can slow it down to the point where the sparks do not land where they are supposed to land, and the edges of the flint gets beat up badly. From what you describe I would check that first.
The spring does not have to be light, but everything has to work slick.
The smae is true with the movement of the hammer and other internal workings.
I have never seen a Pedersoli lock that did not fire properly when it was tuned correctly, and I have not heard of any across the board ignition problems with their locks. Surely if the frizzen were the wrong material or soft they would have hundreds of them out there with this problem (because they make the parts in batches of hundreds), and I have not seen it, so I am betting the lock needs a bit more work.
I will be glad to take a look at it for you if you would like.