Hi guys and many thanks for replying!
In my haste to get the info down without writing out a wall of text, I forgot to mention that the MP3 player module is connected to Software Serial and not hardware serial. Sorry for that confusion!
I've had to draw up a quick and dirty schematic using paint because I usually do my schematics in Eagle in "board house" style which has been frowned upon here once or twice.
I've not drawn in the two 100nF decoupling caps on the Atmega's VCC pins but I do have them close to the pins. I also don't have a crystal since I'm running the Atmega at 3V3 @ 8Mhz Internal and lastly, I have also omitted the 10K resistor which pulls the Atmega Reset pin up to 3V3.
As you can see, everything shares the same common ground. On my actual PCB, I am using double sided FR4 and have used Vias where ever possible to connect top and bottom ground planes as well.
After milling out the PCB board, the first thing I do is go round the PCB with a multimeter either on Buzz or Ohms and look for bad tracks, shorts, breaks etc. Then as I'm soldering in the components, I check each one as I solder it to make sure I've got no bridges, shorts etc until all components are in.
Then, I power up the PCB with no ICs or modules and check I've got voltages where they should be etc and then gradually start adding the IC's and modules, testing as I go so as not to blow anything up
I try to be meticulous and methodical in my PCB building and catch any build / soldering issues early if I can. And it was as I got to adding the MP3 player module when I noticed the current consumption went up despite the buck converter not being on and then I discovered this 0.2V floating around on the MP3 Module's VCC pin. Remove the MP3 and there's no voltage there at all.
Even if I disconnect the Buck converter from the circuit, there's still 0.2V leaking across via the TX Pin on the Atmega IC.
I did contemplate using a pull down resistor to keep the pins pulled low until needed but with the 10K series resistor already in place, I figured that would constitute a voltage divider and would for want of a better description, weaken the signal (Voltage Levels).
I'm also now wondering if this problem I'm having with voltage leaking across the serial pin also relates to another issue I'm having with putting my Atmega into Sleep Mode - which I thought might be a separate problem but now might not be?
Help with Low Power Sleep Mode on Atmega328P - Project Guidance - Arduino Forum
To get round the voltage drain across the Serial Pins issue, I tried to write all the pins I use for Serial comms (hardware and Software) to LOW in Setup, then I write them HIGH when needed and back to LOW again before putting the Atmega to sleep for 16 seconds per time.
However what seems to be happening is, the Atmega will be in Low Power Sleep when it's first powered up and will remain there drawing 190uA UNTIL the atmega has to wake up, talk to the modules and do stuff and THEN go back sleep. It doesn't appear to be going back sleep properly.
After the atmega has done something and goes back sleep, it then insists on drawing 4mA in standby from there on in. I can see the current fluctuating as it wakes up and goes back sleep every 16 seconds or so but the current doesn't drop back down to 190uA
So I figure now that these two issues are connected and it all relate to the serial pins and them leaking voltage across to the MP3 as well as not being turned off after being used properly leading to a high current consumption.
If I could find a way of stopping the voltage leaking across the serial pin to the MP3 (because that's the only module it happens with) and a way to turn off All the serial pins in use (hardware and software) then I think that would solve the problem.
Sorry for the rather long winded post, I'm just trying to get as much info down as possible so it helps you guys to help me
Thanks again!!!!!!!