We can all only provide our own, unique experiences with CBSA and CIC. They're different from other people's experiences because, as we all know, CBSA and CIC can be a bit inconsistent at times. There's no need for anyone to get so hostile and defensive, nobody is saying that anyone else is LYING or anything of the sort. So everyone relax.
CBSA largely operates "by discretion." So some people with an overstay or a failed work permit or something else that's irrelevant to PR might still be flagged in the system, but waved through at primary. That kind of stuff happens. Other people, perhaps with a criminality situation, might have a different experience. Anything that happens with CBSA prior to becoming a PR (overstays, failed work permits, denied entries, etc) SHOULD be irrelevant to border crossings made after you receive PR. That's how it SHOULD work because well, that's what makes sense. Does CIC and CBSA always do things that make sense? NO.
Hopefully an MP can help sort the failed work permit > secondary inspection situation, but PR status gives OP's husband a right to be in Canada regardless. So yeah, perhaps it's a bit inconvenient to have to go to secondary every single time, and it's certainly a waste of everyone's time, but in the end it's not a big deal and it wouldn't amount to anything substantial. PRs have a right to enter Canada, period.