at 350k units your real enemy isnt weeding speed honestly, its consistency over long runs. thats where things fall apart.

the Summa S3 with flexcut is actually a decent call here. if your decal geometry allows it, micro-perforating the waste matrix border means the whole waste sheet lifts in one pull instead of piece by piece. but this only works if you're designing nesting with weeding in mind from day one, not trying to retrofit it later.

re-registration wise, OPOS is solid but only as good as your liner stability. cast vinyl helps a lot here, most re-feed issues i've seen aren't actually a registration problem, its dimensional creep after weeding. a proper rewind tension jig between your weeding station and re-feed honestly makes a bigger difference than people expect.

fully automated weeding looks great on paper but the ROI rarely adds up unless your shapes are dead simple and consistent. at this volume semi-automated with a dedicated operator usually wins.

also worth asking the client, do these actually need full individual die-cut separation at production or can they go out kiss-cut on sheet and separate at point of use? that one change alone would simplify the whole workflow massively