If I am not mistaken, is Vista HAL-independent, meaning that one image can be put on any machine regardless of hardware differences? Perhaps talk to your boss about upgrading to Vista to avoid these problems or getting identical computers for everyone. In the meantime, since you have to do something to clean these computers, why not set them up ideally and then take a snapshot with ImageX and store them on a server somewhere so that this problem can be more easily rectified in the future? Are there no machines that are the same there? Are these all personal computers?