Passthrough issues with alignment on Growth chart


We are trying to make a 6 ft growth chart and for some reason the alignment has issues past the 1’ mark. We are using imperial for the design. It is 10" wide and for some reason we can not get it to read and align automatically, and when we align manually it still is giving either an inch less or up1/4" more in one of the lines. I don’t know if this makes sense?
those that have made growth charts do you have to add a design into the material in order to get it to align properly? the customer wants it plain but we can’t not for the life of us figure out what we are doing wrong.

Thanks in advance for help

A picture of what you are seeing in terms of the misalignment might help the community help you.

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