Jaguar-very helpful.
Minorcan, The problem may be occurring in one of three obvious points in the powder flow path (or perhaps some less obvious places).
1 Cavity not filling. Where the powder exits the hopper-if you have the standard (rectangular) hopper, there is a small baffle above the drop hole and if the powder is not flowing smoothly past that baffle, you can get short charges. If you have the Pro hopper (round one) the hopper has an on-off feature. If the hopper is partially off, you might get the granules of powder blocked up in a "traffic jam".
Solution is to make sure the powder measure gets enough shaking during the loading process - and always exactly the same amount so packing due to the shaking is consistent.
2 Cavity not emptying. Even though it appears the charge bar is moving through its complete cycle, there may be some of the exit hole forming a ledge where the powder can rest.
Solution: Visually make sure that is not happening and add a shake to the powder measure to knock the stalled powder off the ledge and into the hole.
Some people actually modify the charge bar to eliminate this possibility.
3 Clumping of powder in the drop tube. This is rare but will invariably result in an overcharge in the next cartridge.
Solution: Examine your powder supply (and thanks to Smoke & Recoil for reminding me, check the drop tube AND THE INSIDE OF THE POWDER-THRU DIE) to see if humidity or something may cause this.
That's all I can think of at this time.
I have used both the Pro Autodisk and the Standard Autodisk over the years and find them pretty reliable, but have less experience with the adjustable charge bar than the regular disks.
Good luck and thanks for asking our advice.
Lost Sheep