Die cutting and scoring on a cylinder press

I run a miller major and a miller simplex at my fun job. Sometimes while running, the cutting rules will bear off and not cut cleanly. It’s not every sheet and will come and go thoughout the job. I realize the press speed will change the pressure (such as when the automatic oiling system fires up, or when the servos get hot). I have new diecutting jackets on both presses. Also, the other day I was running a simple pocket folder 3 up, when I hear this popping sound not always but only sometimes. After the job was cut down for folding and gluing, it became apparent that the popping was from diecutting on the tabs. Same thing it would come and go. I had matrix on the jacket for the scores. This last Sunday my foreman called me and said he was sick…..could I go in and set up a score and perf on the miller and run 3000….no problem, gravy job. It was, until 1000 sheets in the run that popping noise again . Ugh! I pulled a sheet out of the delivery that “popped” and low and behold it was only an inch of score that cut through the paper on a sheet that was 38 inches long. The only thing I did lately that perhaps could have made a difference …is cleaning 20 years of nasty oil, grease, paper dust, offset spray, and ink off the presses. The foreman said it’s because I cleaned all the gunk out of the roller tracks and now there is too much slop. I offered to sweep the floor and pour it back in ,although we both knew that wouldn’t work. Please help!

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1. Examine the cutting jacket for ‘oil canning’.
2. Ensure the cutting rule is firmly locked over its entire length and is firm on its foot.. The tab bend might just be cocked high a tad leading to intermittant work-up.
3. Look for wear spots on rule bottom edge; a sure sign of movement.
4. Look for dull spot on cutting edge. ‘Crush’, then ‘Pop’ indicates dullness; look closely at the severed edges of the stock for cleanness of cut.
5. Increase packing pressure an onionskin.
6. Mike the offending pieces to determine thickness as compared to other stock. It’s not unusual for varied thickness in some of the heavier boards.
7. Check grippers.
8. Keep fingers crossed and wait for another 20 years for accumulated gunk to resolve problem..

addedendum to 1.
Check for cutting jacket movement and ensure crease matrix is precisely matched and secure as well.

Thank you very much for your prompt problem solving ideas.

send price and picture- thank.