Measure the overall lengths of a few of each type of bullet (base to tip) I'll bet you'll find that much variance in the bullets themselves.
I've had this same "issue" with Berry's, Xtreme's and Rainier's (all plated varieties) I've gotten variances in Hornady 230 gr .45 RN's too, but I can visually see slight differenced in the ogive curvatures.
I'd suggest you "cull" a few of the longer bullets, and use those to initially set up your seating die. (of course check them for chambering & feeding as well) and run the others with this depth "locked-in"
I get some pretty wild variations on commercial bullets, it'll surprise you how inconsistent they can really be.
Another thing, this could be simpilfied if the seating stem is flat & not concave, & seating the bullet by the ogive. A flat seating stem would get you closer to a uniform OAL, it's just those few thousandths of inconsistency will be hidden inside the case, rather than outside.