Finally I found the issue on my report. I was using HEADALIGN=BODY on my TABHEADING and that was the one causing the issue.
In the below example, if you change the HEADALIGN=BODY then you can see the mismatches. Once I change that to INTERNAL, everything started working.
SET LINES=9999
DEFINE FILE CAR
SP1/A6='&' | 'nbsp;';
SP5/A30=SP1|SP1|SP1|SP1|SP1;
SP20/A120=SP5|SP5|SP5|SP5;
EXLPNG/A150= '<IMG src="/wfimages/format_excel_16.png" style="border-style: none" alt="Excel for Analyzing" >';
PRINTPNG/A150='<IMG src="/wfimages/printer_32.png" height=17 width=17 style="border-style: none" alt="Print" >';
END
TABLE FILE CAR
ON TABLE SUBHEAD
" <SP20<SP20<SP20<EXLPNG<PRINTPNG "
PRINT
SP1 AS ''
MODEL AS 'Model'
SP1 AS ''
RETAIL_COST AS 'Retail,cost'
SP1 AS ''
BY CAR AS 'Car'
BY COUNTRY AS 'Country'
ON TABLE SET PAGE-NUM NOPAGE
ON TABLE SET HTMLCSS OFF
ON TABLE SET STYLE *
TYPE=REPORT,CSSURL=/wfimages/dashboard.css,HFREEZE=TOP,SCROLLHEIGHT=2.0,$
TYPE=TITLE,CLASS=head1,$
TYPE=TABHEADING,JUSTIFY=LEFT,HEADALIGN=INTERNAL,COLSPAN=7,$
TYPE=TABHEADING,OBJECT=FIELD,ITEM=1,COLSPAN=3,JUSTIFY=RIGHT,$
TYPE=TABHEADING,OBJECT=FIELD,ITEM=2,COLSPAN=1,JUSTIFY=RIGHT,$
TYPE=TABHEADING,OBJECT=FIELD,ITEM=3,COLSPAN=1,JUSTIFY=RIGHT,$
TYPE=TABHEADING,OBJECT=FIELD,ITEM=4,COLSPAN=1,JUSTIFY=RIGHT,$
TYPE=TABHEADING,OBJECT=FIELD,ITEM=5,COLSPAN=1,JUSTIFY=LEFT,$
ENDSTYLE
END
-EXIT
WFConsultant
WF 8105M on Win7/Tomcat