Are the component leads clean ( not oxidised ) do they boards wet ? Stupid question to ask I know but...
All the components are fresh, and come from the same bag from the manufacturer. Same with the RAW PCB's.
You mentioned oxide build up as a possible cause. Is your tip cleaning station doing it's thing?
Is the tip wetting?
We start each joint cycle with a quick feed of solder wire to wet the tip....
Video may help, I can't find any on my phone, I'll ask the guys in the morning and we'll shoot some if we draw a blank.
As far as I can tell, the tip is wetting fine and it starts off clean every cycle. That isn't to say that there isn't some oxidized solder left around, maybe I need to try flooding the tip a bit more before the cleaning cycle. Or do two cleaning cycles.
The program I currently have in is a cleaning cycle, and the program feeds some solder onto the tip to wet it before starting the first joint.