The family name is Wilkerson I think. I read it a while ago when I was looking the show up online, but I don't think it's ever been mentioned in any episode (apparently a mention of the family name was cut out of the pilot episode).
Springfield...it's not actually anywhere. Some fans tried to piece together its location based on all the clues in the episodes, but a lot of it is contradictory. Maybe it moves around the country? We don't know where Malcolm's home is either, but it's filmed in California.
Fat guy's Craig. I don't really have a favourite episode.
I started watching at the beginning of Season 4, and I watched most of Seasons 2 and 3 after that...I caught up on Season 1 since they've been showing it on Sky One recently (they just moved into Season 2 though). Season 2 opening episode was fecking funny. Truck's crashed on the motorway and all the traffic is held up. Lois phones up road services, and the guy's not being very helpful.
LOIS (shouting): Let me speak to your supervisor!
MAN: OK, hold on a minute ma'am.Two seconds pass
MAN WITH DEEP VOICE: This is the supervisor.
LOIS (face distorts): Wait a minute, this isn't the supervisor. This is you! Stop playing games with me Mister! You can't do this to me!
MAN (back to normal voice): Look lady, I'm going to be replaced by a machine soon. I can do anything I want.