That is pretty bizarre.
When you say "every other run", how are you running the app? Build and run? Or just run?
If it is build and run, do you have any custom build phases that copy files or do any custom processing?
The backtrace indicates that is is crashing during NIB loading, specifically when it is setting an outlet. Any chance you have the wrong object as file's owner? Maybe a different code path depending on what is read from the filesystem at app launch?