Hi Ludek,
Thank you for your quick response, and I apologize for my own delay. Good news however, we believe we found the cause of our issue, and I just wanted to share it here in the off chance that someone else is running into the same issue.
So it seems that the problem occurred so intermittently because the problem we were running into was caused when we attempted to close our crystal reports form before the OnShown event had completed. This was happening because, as I mentioned in my initial posting, we were caching a crystal reports form for speed, and were calling the show and close function back to back.
We were able to use SychLock to ensure that these two events executed on the same thread, and this seems to have resolved the issue for us.