In my experience you get this error also in cases where the application window the robot is trying to manipulate, is for some reason moved partially outside the desktop. Or in cases where an application has a window within a window and the inner window is not fully visible to the robot.
For example we have this one application where the windows inside the app’s main frame window randomly move and are not fully visible. The robot must always try to move the inner windows to the center of the main frame window before it tries to do some UI activities on the inner window.
One special case where you might also get this error is that the automated app needs for example a Full HD resolution for operation, but when the robot is launched unattended, it gets a lower resolution. I was able to fix this kind of issue with Launch Workflow Interactive activity and by increasing the memory of the system’s graphics card.
I hope this explanation isn’t too unclear…