A couple of Q’s & Comments:
1. I assume that Canadian & ANZAC units must be built in their respective areas… Do the UK Home & Far East Command units have to likewise be built in one area or the other depending on where their IC’s came from?
2. Do the Red Chinese move on the Soviet turn or the Nationalist Chinese turn?
A couple of preliminary thoughts:
a. You should combine the US & Nationalist China turns in much the same way as the UK-Commonwealth turns are combined, and allow the US to send air units to reinforce/ replace the Chinese “Flying Tigers” unit if they can logistically get there. Also, Adding Chinese dispositions to the blank section of the US chart can save you some space, too; the blank page on several of the cards looks awkward, I think.
b. Along the same lines, I’d do like you did for Japan, and fill in the blank page for the rest of powers that still have one by moving either naval or colonial Far Eastern possessions to the blank fourth “page” of the card.
c. The Dutch ought to get at least a destroyer or two, a sub and maybe a cruiser. Their ships (at least 2 cruisers if I recall, + several destroyers & subs) were key components (numerically, anyway) of the early-war ABDA Command, until Japan managed to hunt them down.
d. As an alternative to moving all naval dispositions to one side (as suggested by b), you could also move the “pro-allied neutrals” to the blank side of the France card and combine them as a semi-separate “allied minors” category that moves with France and do the same combining with the pro-axis minors and Italy. This could simplify the cards and save a whole page. You could go further and simplify the whole game somewhat and give France and Italy a little bit more oomph to work with if you also combined their IPC’s with those of the respective minors, which is a separate issue from merely occupying the same set-up cards.
Generally, though, I like your set-up charts. I might use them as a foundation for my own variant. You should print them up and sell them once you have them perfected.