It is certainly possible for it to happen, but only if you are using two cards from the same supplier with the same fixed MAC address. I have certainly come across - and even made - cards where the MAC address was compiled into the software or chosen from a couple of options using DIP switches. These cards would not work together on the same network. For the cards I made, that was perfectly acceptable behaviour - and having the same MAC address meant getting the same DHCP address during testing and development, which was an advantage.
If you are talking about a conflict between two independent cards, then the chances of that happening are /really/ small. It is not impossible, of course.
Yes. And if the customer expects to be able to use the cards in a random network, then you have to provide a unique address or at least an address that is highly unlikely to be a collision. (You can never be /sure/ your address is unique - someone else might have randomly picked /your/ address - and even if it is not your fault, it might end up being your problem.)
I don't disagree with you here - that is undoubtedly best practice. It is just not the only practice used, and remember that "good enough" is often good enough - you don't always have to go for "best".
If someone replaces the switch in the production line without checking the relevant documentation and consulting the relevant people involved, then we have a bigger problem than just a MAC address conflict. That's what procedures and quality control rules are for. (It's also why there are clear labels on the switch in question, in case someone makes a mistake.)
Yes, I am ignoring IPv6 in this case - because I am not using IPv6 here.
And even if I were using IPv6, it would be perfectly possible to use it while the cards all had the same MAC address but different VLANs. IPv6 is not /that/ different from IPv4, and the only MAC address connection is that MAC addresses are sometimes used to give an IPv6 address to a port - but there is nothing hindering the DHCP server from giving each card a different IPv6 address on the different VLANs, just as it currently does with IPv4 addresses.