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There has to be something in your sequence that may have caused the snag. 

Will it be alright for you to give us a rundown of the action and a screen shot of your image layers?

addendum .... Or that the recorded action is looking for a particular layer which existed  in your original file when you created the action but does not exist in your current file. You may have to recheck and examine the action with the file you used to create it then try it on a new file if the sequence flow suits it.