Hi,

Here are the answers to your queries.

a) The first issue to tackle is do you have SP-2 installed to Project 2010?
Ans - Version 14.0.6129.5000 (32 bit) - Not sure about SP-2 or SP-1

b) Are you using automatic leveling?
Ans - No, we are not using automatic leveling. Its manual

c) If you open a file, press F9 to recalculate and then save, does that help?
Ans - No, it did not help.

d) If you open the file and immediately save as another file name, does that help?
Ans - No, it did not help.

e) I'm not sure what you mean about increasing the column width. Are you saying the file size increases?
Ans - By Increasing the column width, I mean expanding the columns, the size is increasing.

One more thing I observed is changing the font also changes the size of file which I feel is genuine.

Please share your inputs. Thanks