Hi,
Besides the obvious reasons (plugin disabled, not with "public" access, "last cron update" date in the far future, cron not running, etc), here are things that could be problematic:
- if you have the "notify" option activated, it will send an email notification for each order. Sending an email can take a long time, and if there is a bug in the email notification generation, it can crash the process, stopping the status change of all the orders being processed.
- the plugin will only be changing the status of 20 orders on each cron trigger in order to reduce the possibility of a crash during the processing, so maybe it's actually working but you didn't notice. If you have 4000 orders to change, and the plugin is triggered once every 6 hours, it will take 50 days to process all the orders. Note that the goal of the plugin is to process the new orders. Not to process a backlog of 4000 orders. So I would recommend to first do a mass action for the really old orders and then you can let the plugin handle the new orders from that point on.
- the plugin will use the statuses configured under the "created" and the "cancelled" columns of the System>Order statuses menu. So maybe there is a problem with the way the statuses are configured ?