Hi Christoph.
I'd realised that once i made the post, and yes, the duplicate and flatten parts in the process are unnecessary, they have been removed. The action is set up now so that once it crops the individual images, it closes the main image down, and then saves and closes the individual images. It is setup to save and close 12 images (as this is the most there will ever be in my case), and I set the action to post errors to a log rather than halt, so if there are less than 12 files it will continue and just post an error in the file. It works really well now thanks!!
I then run an action that options each individual file and brings up the "save as" dialog. This is a chance to perform a QA on the image and to save it as the correct name on the plan.
However, the action is currently setup so that it creates a complete new image each time and closes the original. This is the only way I can make the "Save as" dialog point to the new destination as if I simply open and "save as" the original files, the default folder always resets back to the original folder where the cropped images are. I'll have to investigate other methods of opening and renaming the images to help speed this part of the process up.
Thanks so much for your effecient responses. They have been a great help!
Cheers.