the bus takes 4.5-5.5 hours to reach KL, and one stop on the way around 1AM. Even the seat is spacious, you won't sleep well as the light of other vehicles make you feel very disturbed.
Check in hotel, normally should be after 12pm. check in at morning is normally not aaccepted.
from 5am to 11am, hehe, of course you can not finish visiting those places mentioned.
There are a lot of hotels/huest houses on Phuket, however, your are bringing family alone and stay in guest houses with backpackers, it is a joke and you won't enjoy it.
As it takes time to go Phiphi island, without staying there for 1 or 2 nights, it is a waste of time and money.
Go Krabi for one day is not a smart choice. you can get nothing by staying just 24 hours there.
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The biggest problems here are two:
I am 100% your can not survive if you travel to so many places in such a short time period. your child and parents will not enjoy it unless you cut the number of destinations to less than 50% of planned ones. I spent 4 days in phuket and feel very relaxed, while I tried to cover bangkok and Samui in 7 days and missed a lot of things and very tired after 1 night on bus from bangkok to Surat Tani and 1 night on the way back from Surat to Bangkok.
You are strongly suggested not to plan such kind of budget travel for elderly and young child. I am sure they won't enjoy it.