I am working on systems that have less than a %1 failure rate per day, but it's very annoying when it happens.
This is using Windows 7 (embeded - POSReady).
We've replaced explorer.exe as the shell with a C# app. This app is a full size GUI that also launches a few other programs.
The problem is, on rare occassion (less than %1) after a reboot, nothing starts. The GUI app logs start, the applications that it starts logs start - but nothing ever shows up. Just a black screen. Logging off/on always fixes the problem.
I can log in with remote tools, open task manager and see that none of the executables are running. I can remotely start the GUI app and everything starts as expected.
We are running a whitelisting and virus scanning solution - both of which have been extensively examined and no evidence can be found indicating that they killed these applications.
The GUI application starts subordinate processes independent of itself (there is no child/parent relationship).
I'm running out of places to look. Looking for ideas.