Door & jamb hinge templates

I've been using Templaco's hinge templates for several years now. I just installed 7 solid 6-panel doors with 3 each 3 1/2 hinges. All of the doors had the bottom hinge set in too far (pinched the door when closed) and the door went from flush with the jamb at the top to 1/4 inch out at the bottom. I used the same template setup and a router that is setup for the templates and never gets used for anything else.

Any ideas what I done or what could have happened.