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My basic advice would be to stop using preprinted forms and instead use Forms Designer and data mapping tools to create "soft" forms that you can then drag and drop the print data onto. Everything will always line up that way, plus you open yourself up to being able to save the output as a PDF, etc.
The reasons for eliminating preprinted forms and the headaches associated with them are numerous. I have done whole presentations on this topic at technical conferences. There are many packages on the market that do this, although I have a bias towards IBM Infoprint Designer. Once the forms and data mapping are done, everything runs natively on the iSeries -- no need to move data back and forth between the iSeries and a PC server.
Admittedly, IBM Infoprint Designer can be difficult for some people to learn, although anyone I've ever trained and worked with has had no trouble after training.
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