At what range and what MV is this occurring?
Does it happen with all loads he has tried?
First thing to look at is the barrel bore. If there is any pitting, what can happen is that bullet material lodges there and builds up until at some point the clag is removed all in one piece, destabilising the bullet, barrel is now relatively clean again and the cycle repeats.
I presume that his meticulousness includes control of COL.
Other possibilities:
Twist rate is not compatible with bullet weight - but marginally, so that some bullets are not stabilised. (Bit of a stretch this one). Could try some significantly lower MVs, or higher if safe.
MV is supersonic but falls to marginally transonic (and hence unstable) before reaching target - higher MV would prevent this - or lower so that is subsonic at muzzle if this is practical.
Crap bullets? Does he weight match them?