Welllll, this may not be a lot of help, but my VS540 would print, laminate, read the registration marks, and cut pretty well for the first 5 years....then NOT!
I would run two sets of the identical job, ( just for ease of handling & laminating). I would put one back into the machine to cut, and it would read the reg marks, and cut pretty nicely. The second one, it would read the marks ( no errors or repositioning) and cut absolute garbage, like the job was 5 or 10mm wider! No amount of trouble-shooting would resolve something as random as this.
Is it a problem in Production Manager? the Optical sensor? Nothing would explain how it cut the first one perfectly, and the second not.
I've given up, and don't use it for print/lam/cut anymore.....you might have to resort to printing reg marks and cutting on another plotter with OPOS.