Workflow Inconsistant

We have started using workflow for our batch approval. We just took the canned JDEBCHAPPR and created our own version with some small tweeks to use external mail. It works great most of the time, but we have certain times where a batch is created and no workflow is created, and other times where only the first of the two emails are sent, even though someone has approved the batch (the workflow should be completed at this point). Has anyone seem similar things?

Dave
E9.0, Tools 9.1.0.4
Oracle 11g