Not sure if this will fix the issue or not, but have you considered a later start and then staying through the rest of the day without a break? I know one of the tricky things about AK is the timing since so much of it is scheduled shows and appearances. A lot of what you have on your schedule is only available at particular times. That may be what is not letting the FPP register appropriately. Too many other things have to have that time slot. With so many things needing afternoon time slots, I wonder in having a later start and then not taking the afternoon break would help.
That is also quite a bit of running around (and I’m a RD to close kinda girl). I would think about priorities and then have some backup activities in mind if you end up having time. I just did this with my 2.5 year old niece. I took out the Hakuna Matata Time dance party, which helped the schedule, but we were still able to walk past it and dance a little on the way to Nemo. Setting a relaxed walking pace allowed for short detours like that.
One obvious thing I see is to move the trails around to whenever you will already be in that area. As far as potentially cutting down, those would be my other things to focus on, deciding which ones you really must see (keep on the plan) and which you can just know are there to enjoy if you get ahead of schedule. We decided not to prioritize them as much because my niece has a beautiful zoo in her hometown so they were not as unique of an experience compared to other options
After also starting with a crisscross mess, our general order on the last trip was:
Adventurers Outpost (FPP)
FOTLK (first show)
KS (FPP) - followed by a brief tour of the gorilla trail
Flights of Wonder (brief tour or discovery island trails)
Nemo (stopped at HM dance party)
FOP (planned to do Triceratops but we scored a same day FPP for FOP so skipped it for that)
Rivers of Light
Dinner at satu’li to see Pandora at night
That was a pretty busy open to close with no break - though lunch took about 2 hours. It was also a CL10 so busy moving from place to place, though lines never held us up because we always had FPP for everything with a line.