Cutter is 1/4 off cutting digital prints randomly

[Rat_Fink]

Graphtec FC9000, Mutoh XpertJet 1641 SR Pro and Flexi 22.
Until a bout a week ago, this setup has been flawless.
Now, print files are randomly cut approx 1/4 off (always shifted toward the back of the cutter).
These are files that I have printed numerous times in the past and I have not changed any setting at all.
I wouldn't think it would be a calibration issue since this happens randomly.
In the photo attached - the job on the left has the cut line shifted approx 1/4 to the right (the way it is fed into the cutter is 1/4 toward the back) and the job on the right is a reprint of the same file and was cut normally.
I do not know if the problem is with the printer, the software or the cutter. when it does happen, the distance and direction of the shift seems to be the same and is the same throughout the entire cutting area. It's not like it is correct on the beginning then drifts toward the end of a long cut.
The only thing that might have been done between the jobs is a reboot of the devices - but as mentioned, this has never happened before approx 1 week ago.

 

[Rat_Fink]

After thinking about this issue a bit - it seems to me that the Graphtec cutter is still acting like the blade is in the position for perf cut even though it was switched back to kiss cut.
So I have condition 1 for normal cutting with the blade above the cutting strip. I have condition 8 for perf cut with the blade in the forward position over the gap.
Even though I put the blade in the correct position and set the correct condition, the graphte cseems to still think the blade is in the forward (perf cut) position. It still does the correct, normal cutting, but it is approx 1/4 off.
I think shutting the cutter off and powering back on fixed it - but then it randomly happens again and ruins more jobs. I feel that I should not have to shut the cutter off and turn it back on after each job just to be safe.
Has anyone had this happen?

 

[Solventinkjet]

Are all your settings the same as before this happened? Maybe the battery on the main board is dead and certain parameters are getting set to defaults every time you power cycle?

 

[Rat_Fink]

Everything is the same. As I mentioned on my second comment - it appears that after doing perf cut with the blade in the forward position, I move the blade back to the rear position / set the correct condition for normal cut - but the cutter is treating it as if the blade is still in the forward position in terms of where the origin point is located (approx 1/4").
I'm not sure if this is actually happening, but it seems like that would account for the 1/4" difference in only the X/Y direction