Given:
- A VSTO Add-In
 - An 
override object RequestComAddInAutomationService()which returns an instance of a class which is calledFacadein my scenario. - A VBA macro in Excel 2007 which accesses the 
AddIn.Objectto get the Facade and uses it. - A plenty of times where this works perfectly fine.
 - A couple of times where out of the blue, this doesn't seem to work.
 
Update: Turns out that it's a particular user that has the problem. She has it all the time, others never have it (? never say "never")
In this "couple of times" I get
Error: Object variable or With block variable not set
at the line of code which tries to access a property of Facade. In short I can tell you that the code in RequestComAddInAutomationService() doesn't have any error-prone magic in it, and the VBA code to access the add-in has been taken from the web and looks fine, too. The longer version is yet to come, for those who'll take the time to read it :-)
Question: Does anyone have a clue why this can happen? Is it an Excel issue?
Details as promised:
MyAddIn.cs:
public partial class MyAddIn
{
    public Facade Facade { get; private set; }
    protected override object RequestComAddInAutomationService()
    {
        if (this.Facade == null)
            this.Facade = new Facade(Controller.Instance);
        return this.Facade;
    }
}
Facade.cs:
[ComVisible(true)]
[Guid("1972781C-A71A-48cd-9675-AE47EACE95E8")]
[InterfaceType(ComInterfaceType.InterfaceIsDual)]
public interface IFacade
{
    // some methods
}
[ComVisible(true)]
[ClassInterface(ClassInterfaceType.None)]
public class Facade : IFacade
{
    private Controller Controller { get; set; }
    public Facade(Controller controller)
    {
        this.Controller = controller;
    }
}
Facade has some methods but not a single field.
Controller.cs:
public class Controller
{
    private static Controller instance = null;
    public static Controller Instance
    {
        get
        {
            if (instance == null) instance = new Controller();
            return instance;
        }
    }
    private Controller() { }
}
Controller has some private fields. Since the fields assignments are executed on creation, I reviewed them. Most of them are not initialized at all, or they are set to null, so the constructor does virtually nothing.
The VBA code:
Dim addin As Office.COMAddIn
Dim automationObject As Object
Set addin = Application.COMAddIns("My AddIn")
Set automationObject = addin.Object
Dim oResult As Object
Set oResult = automationObject.SomeMethodThatReturnsAnObject()
The last line is where the error happens. Although the method called returns an object, I am pretty sure that it cannot be the source of the error: If the reference returned was null, then the statement would simply evaluate to Set oResult = Nothing which is still valid. VBA rather throws this type of error whenever a method is executed on an reference that is Nothing, which is automationObject in my case.
On the other hand, if the add-in wasn't there at all, the Application.COMAddIns(...) would raise an index out of bounds error, I've seen that before.