ROBOT_G - yes that was part of the problem. We remastered all the joints and that issue cleared up.
pdl - we use a bag flattener. We spent time tightening up bag pickup location as well as pallet location. We now have very little variation in both.
We also confirmed that the x-y Coordinates displayed on the teach pad at the drop coordinates are consistent from pallet to pallet but the physical location seems to suddenly shift after several pallets.
We go from good to bad and then we have to readjust the setting for each bag x-y offset. Works for a bit then goes bad again. Could it be a gear issue? Encoder issue? Motor issue?