Well, this is interesting. With those settings to check for unroutable sims on shortly after the start of a new game I found Bebe Hart stuck halfway in the wall of some community lot no where near her home. I have no Idea how she could have even gotten in such a predicament so I just teleported her out and didn't give that one a second thought.
The only other one that is popping up a lot is the news paper delivery girl stuck in the lobby of the apartment build containing the NPC door she got assigned to. This one baffled me a bit. I sent my sim over to see if the door was locked or something but my sim was able to walk in just fine. I tried resetting the door with debug enabler but still she just stands there going through her idle animations. She wasn't stomping her feet or anything, just standing there not moving.
Then I realized, I have a mod installed that prevents newspaper delivery and now I know how. lol I thought it was just my active household that wasn't getting news papers. I didn't realize no one in town is getting any. Oh well, no worries there.
I'm playing on triple speed hoping to expose routing issues faster. I pause when ever I see a notification come up and then unpause after reading them to make sure I don't miss anything. But so far nothings turning up yet. Except that newspaper delivery girl.
Man I feel like this thing so close to ready for release but I know once I do I'll think of a dozen other things I could have done. It's exactly that phenomenon, the second guessing after the fact that caused George Lucas to once say, "Movies aren't released. They escape."