Interesting. I had exactly the opposite experience.
Last year the brass I loaded up for FCNC was the same stuff I'd been using all year long, with all the appropriate prep - dry tumble, anneal, size, trim, tumble lube off, brush the necks, apply some Imperial dry neck lube... same schtick I'd been doing. Suddenly had some rounds that felt off, that the seating force was notably lighter, along with a few that were definitely heavier. I disregarded that, and paid for it on target with some very off-call shots (vertical). I meant to get around to sorting that out, but between one thing and another, it didn't happen. Still have ~100rds of that ammo loaded up, and that barrel around here somewhere, but never got around to tracking down the why or wherefore.
Then started loading ammo for the SWN this year. Different brass, known-good from 2017 FCWC cycle, no issues during load development. Had an occasional few that were lighter, that I just used for sighter/foulers as I was mostly shooting small batches. Then when I started loading several hundred for the match, I really started noticing it again. I have a hydro seater, but it's not part of my normal regime as the die I use with it is a royal PITA. On the hydro seater, the 'normal' seating force was in the 30-35 range, the 'light' was in the <20 range, and the 'heavy' seating force was >50. Actually the 'heavy' was more like a 'pop' (felt, not audible) at the case mouth, then basically normal seating force. The effects (normal, light, heavy) were enough that I could definitely feel it even on my regular press (550 w/ Forster Ultra BR seater).
This time I was a *little* smarter than last fall. I started taking the ones that seated light (because they were more common, and the ones I thought were the problem) and coloring the tip with a blue sharpie so I could identify them in the box. Later, I decided to start taking the ones that seated heavy and color them red. Figured I had a number of strings with unlimited sighters, and I'd do a little experiment at some point.
So on that Tuesday during squadded practice @ 1k, I got the gun centered up, holding pretty decent waterline with the ammo that had 'normal' seating force. Then I shot 5 of the 'blue' rounds (remember, these were the ones I was expecting to be 'the problem') - right in with the others, indistinguishable from the first group. Hmmm... then I shot 5 of the red tipped ones, and yup, there it is: nice tight group, but a good 1 moa low and .5 moa right, skirting the 9 line, into the 8 @ 4:30. Just for confirmation, I shot 5 more of the 'normal' ones, and bam, right back up into the X-ring.
The good news: I confirmed that there *was* a definite, measurable difference going on, and it wasn't anything to do with the nut behind the trigger.
The bad news: apparently I need to fire the guy loading the ammo
The worse news... I didn't 'wise up' and start marking the 'red' ones until about halfways thru the loading session. So there were one or two boxes that were like Cracker Jacks... a few hidden 'surprises' still lurking in there
Things have been slightly nuts here since that match... probably going to be sometime *next* month before I have a chance to fire off the remaining ammo, and dig into WTF is causing that weird 'pop' on some cases when seating. I checked some of the usual culprits that came to mind (burr inside the case mouth, etc.) at the time and came up with nothing.