Having seen a lot of similar issues, I can say I feel your pain. It can be really frustrating to get to the root of these issues, and when you do, management is

Having seen a lot of similar issues, I can say I feel your pain. It can be really frustrating to get to the root of these issues, and when you do, management is rarely willing to accept the answer of "We've done all we can, the root of the problem is a device flaw we can't change." How recent of a jffs2 image are you using? They've implemented some block tables in newer versions that speed up mount time a lot if my understanding is correct. Also, I would highly recommend trying out UBIFS if you get the chance - it's jffs2's successor, and well implemented.