Thanks for your input.
I heard about the component size from someone else as well. They said if the component is greater than 8.4mm, it will not load another component next to it on an adjacent head, which is only 16mm away. The PLCC6 LED's are 5 x 6.5, which is only 7.2mm diagonal, so I don't see why this would cause the problem.
I was also told that if the LED's were more than 8 feeders away from the resistors, that it will place the resistors, then come back for the LED's. My LED's are on feeder 23, and my resistors are on feeder 33, so this might be causing the problem.
I am going to fire it back up tomorrow, and do some more checking.
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