Regarding point 1, NPrinting On-Demand requires that you are on IE 10 at a minimum. I don't believe that is causing your issue as your DEV machine with IE 9 renders the report just fine and you are not using On-Demand anyway
You do not require Office if you are generating HTML reports, so point 2 is N/A IMO.
I suspect that your QA project is accessing a QVW (via a Connection) that is saved with WebView turned on. This can cause unpredictable layout issues. Is this the case?