Weird problem with outlines

I'm having a weird issue with creating outlines. I'm trying to create an action to expand an object/text, then use Pathfinder>Unite to merge it all as one, then Pathfinder>Outline. This works for most objects, but a few random ones end up adding some small lines on top of the outine. This would be fine normally as you can't really see the extra lines, but I'm printing to a laser machine and this adds extra cuts that shouldn't be there causing my cut lines to be all wonky. The first image is how it looks before the action is run (3200% magnification), the second image is how it comes out, the third image I deleted a line segment to show the extra lines that appeared. I can't figure out why this is happening and it's driving me crazy!!