Every bullet manufacturer has some sort of tolerance in their process the same way that every manufacturing process has some sort of tolerance applied. Without it, nothing would ever pass a quality inspection as there will always be variation. No bullet manufacturer is immune to this. Getting hornady to cough up the actual tolerances they use probably not going to happen. But it is quite possible that the have tighter tolerances on their match bullets.
Your gun may smell berger, but your gun may not like berger. As some have previously mentioned depending on how you measure your jump, base to ogive or base to tip, you can get drastically different measurements. Measured a bunch of 215 bergers and the base to tip of the bullet varied approximately 0.015" across half a dozen bullets from the same box (which appears to be similar numbers to what you measured on the hornadys). They shot great and jump was consistent because they were measured/seated off the ogive not the tip.
I would just take it as a learning experience. If you have a new lot of bullets you should go back and check to make sure that your previously measured jump is accurate. Its something I have to do with sierra gamekings as the lead tips are inconsistent even within the same box.
Just curious. Did you try loading the new lot of bullets to the same jump you started with and same powder charge previously used? How did they shoot?
