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I would clean less, and print more.
The less you touch these heads the better.
Is it always the same nozzles that are out? Those few nozzles missing wouldn't be seen in any print - in my opinion.
Could be some nozzles aren't firing. Sorry I don't have a better answer for you. The orange print does look like you are losing nozzles.
It's true that you'll sometimes have a perfect nozzle test and then a nozzle can drop out when printing.
Not really related to the problem you're having...
It doesn't look like a "color drop out across the board". Looks like once it gets up to temperature, your feed calibration is off.
But then again, you've only shown one image.
Sounds like you're sure you know what it is. Does your RIP allow you to print colour bars on the side? That might be useful to see which colour is having the problem.
The first image looks like feed calibration.
You say " up to 6 pass". That's our go to, except for banners.
Have you tried...
Doesn't look quite like silvering to me. Looks like dust or material defect.
If you press hard over one of those spots, or heat up one of those spots... or both - does it reduce the silvering?
Nice document. I think it's the feed rate and nozzles are fine. 6pass should be fine always, if the media adjustments are done correctly. I can get 4pass on some matte vinyls to look perfect as well.
Have you tried a feed calibration? Try the auto version in "Media Adjust".
I would try it with the takeup reel attached, then perform that operation. I'm guessing you won't see that banding again.
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