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Print to Plot Issues

We are having issues when printing and then plotting jobs. Specifically jobs that are over 4' or more. Under the four foot dimension, we can get match up perfectly. Over 4 foot, we can have as much as a 1/16" out of alignment. We have tried running smaller test runs to check calibration, but they always come out fine. I don't know if our vinyl is stretching/shrinking during printing and it becomes more and more noticeable over the longer runs? Or?? We are running Flexi and have an HP365 and a Graphtec FC8600. Any input or help would be appreciated. 

Thank you!

Location

Telge Road
77429 TX
United States