Nothing unusual about your findings. Sort for base to ogive length, rock on. Learning curve is a bitch. Next lot number you buy will be different, so buy a 1000 at a time, sort, you are good to go.
Now understanding why this happens is key so you can be realistic in your expectations. The company may have one machine running the bullet with only one point up die, but I doubt it. Setting up point up dies is exactly like adjusting your full length sizer to size your brass for the chamber size. The more you screw the point up die down, the further down toward the base of the bullet the ogive moves. Of course the operator's experience is critical.
The shorter base to ogive measurement will produce a lead level that is further up bullet also, and this has an effect on the balance point of the bullet that your barrel may like or dislike.
linkage on the press or machine can cause variations in Base to Ogive length, jacket thickness, along with thickness of the lube.
Likely that Hornady may have more than one machine running a bullet with the base to ogive length set to be within a certain spec. I would bet that they sort bullets off of each machine as a different Lot #. Machines wear, dies wear and you have to be aware of this when you decide to shoot a "production" bullet vs a bullet that is made with a well trained elbow on a low production Rockchucker or RCBS A-2 press.
So, sorting bullets should be the norm for a serious precision shooter. If you do not want to sort bullets, then buy bullets made from a guy that has a well trained elbow. You will still have too check your bullets, any way you go, especially if your rifle is real picky on distance from the lands. Experimenting with a 0.000-.003 change in base to ogive should be part of your load development...how wide is the tune window.