Documentation of the roll tooling setup is important to maintain consistency and repeatability. Some Trouble Shooting Tricks of the trade are: Check the part out of each pass to ensure that the pass is doing what it is designed to do. Checking the mill face or machine face alignment to see how accurately the roll former is aligned station to station and top to bottom. If you think the problem is isolated to one particular pass cut the material on either side of the pass and raise the roll tooling up so that the material can be removed and inspected to see what problems are there. Backing up the roll former a few inches can allow you to look for pressure marks, misalignment problems in a radius, or if the roll stops are being hit too hard.
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