Going off memory, Characters were NOT out until 10am. DS & I were at the gates at 7am, gates opened at 8am, we went straight to JTA (got first show... 9:15), got FP for Star Tours (8:30AM), rode Star Tours, got FP for TSM (2pm I believe, didn't have time to ride standby), and by that time it was around 8:45 I think. Characters weren't out.
By the time JTA was over (9:45 or so), the lines were formed for the characters at the 'set locations' and the characters came out at 10.
FWIW, we didn't really have a plan other than getting him in JTA, but here's what we *DID* accomplish (in no particular order):
Star Tours (x2)
JTA
Indiana Jones
Galactic Senate (see picture on previous page)
Clone Troopers
Jawas
Chewbacca/Wicket
Jengo Fett
R2D2
SW Parade
Commander Cody
DHS Afternoon parade (don't remember the name of it)
Hyperspace Hoopla
TSM (DD & DS only)
I think it was probably the best day in my son's life... we were looking at the pictures again last night and he's ready to go back.