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Without knowing specifics about your environment, I'll make an educated guess. Do you by any chance have more than one replica of the public folders hosting the forms? If so, then have a look at (a) which public folder replica your Outlook clients are hitting (i.e., affected by affinity) and (b) public folder replication.
At first glance, it sounds like some of your Outlook clients are hitting replicas that contain the forms in the folder form library, while other clients are hitting replicas that for some reason don't contain the forms.
If that doesn't apply, have a good look through the application event logs on the Exchange server(s) hosting your problematic public folders and check for any suspicious errors (or warnings), specifically any from the MSExchangeIS Public source.
Do you have comments on this Ask the Expert Q&A? Let us know.
Related information from SearchExchange.com:
FAQ: Exchange public folders
Reference Center: Public folder management
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