I believe we have found the issue and wanted to let you know what it was. We saved some specific points to go back to and verify the direction it was moving in. It had changed again this morning and we found that the tip that the silicon is being dispensed out of had moved, not the robot. The part is picked up by the robot and traces the tip of the stationary silicon applicator. The tip is held by two bolts but doesn't have alignment pins and can move in the Y direction only approximately 4mm + or - if it is contacted. I checked this the other day and it didn't seem to have any movement, but I was able to move it this morning. We are going to add a support to keep this from moving. Thanks for your input.