I've noticed the plotter get worse on contour cutting a lot more recently. The job I had yesterday was only 24in wide by 8 in tall. The plotter has always shown offset error however after reading. So I have never had a perfect contour cut ever
The constant error may well be fixed by going through the routine for setting the blade to mark sensor adjustment as outlined in the plotter's manual. If this setting is off then there will be a constant error when contour cutting.
As for getting worse, is it worse in the carriage or media feed direction or both? If in the direction of carriage feed one would suspect a loose belt or worn or contaminated carriage positioning tackle. If in the media feed direction perhaps the media feed compensation is not right, i.e. what your software thinks is an inch and what the plotter thinks is an inch. If in both directions it may well be software or some bizarre combination of things.
Note that various settings, once set, do not change unless something changes them.