It could be that it is very slightly out of alignment for focus, mine (on a canon system) is OK on my bodies where I can do micro AF adjustment, but if I use it on one that doesn't have this the results are not great. I'm going to be sending mine in to Sigma with one of the spare bodies so they can get it spot on.
Although, it could but just that you are moving a little in your case. Go for the tripod test, good light, well defined subject and centre point only focus.