a few things might help:
- use the same printer drivers if possible. either you have the same printer driver as your customer, or your customer has the same printer driver as you. also need to see if there is a postscript version of the driver. customer needs to always work on the Word file with your printer "active". of course, if the customer does not have the same physical printer as you, then creating hardcopy proofs "at home" is a problem.
- there are lots of differences between printers: dpi, lines per inch, "grab" margins, etc. that can affect page reflow. i have noticed on HP laser printers that staying in the same model range (e.g., LaserJet 5, 5000, 5MP) does not cause a significant change in the document flow, but changing from a 5 series to a 4 series can create changes. i have not fully tested this out, but i have had need to print the same word document out on a 4 and 5 series, and a digital copier also.
- when exchanging files, ask for the fonts. Or, have the customer limit font choices to Windows default install fonts (again, probably need to be on the same version of Windows), or customer has same fonts as you. please note that there are font licensing issues that can prevent copying of fonts.
- if you use distiller as the printer, be aware that distiller does have its own "settings": page size, margins, dpi, etc. that can affect page reflow.
- graphic images shouldn't change when opened on another computer assuming that the graphic image is embedded. if there are problems, probably need to check: how the graphic file was made, file type (especially if compressed using jpeg), linking vs. embedding, etc.
hope this helps
mike