This has happened to me many times!!! I have no clue what it could be. I even had this happen to me many times during the CAS Demo.
The only thing I do about it now, since I haven't found a solution, is quickly edit the features of the face and body size and personality and I leave the clothes/hair/makeup for later. I get the family done and saved and move them into a house and from there are go to a dresser and edit clothes. Yes, it is a longer process and doesn't really fix anything, but at least the family is saved. Hope we figure out something for it soon!