I've never had a real problem, and I've had bank cards for well over 20 years from 3 different banks as well as credit cards from several different companies!
The nearest thing I had to a problem recently was when one was sent out 3 months early, and I nearly cut up my old one before the new one started

I did have an issue when I lost one (later found down the back of the passenger seat in the car). They sent out a new one and promised me the pin would be the same. It wasn't. I had changed it years earlier, but the new card had the original pin from before! I was in Toys 'r' us holding my little pony when I found out. It was quite embarrassing, but they let me sign for it instead. That was a while back.
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