Just an update and a few comments.
My rep has been contacted by either some people here, or some people who relayed the msg from some people here. He contacted me and is coming out to see us next week and says he can fix the problems. I'm not confident, but I do think he understands the gravity of the situation.
So thanks to everyone for their help.
bentherdontat.. Yes, I thought of the same thing two pkgs "stuck" together. I also learned about 3rd party companys assigned to this task. There does need to be a program to police abusers of the system, (I am sure there are many) but frankly the system in place does not seem to be it for us. There is incentive for the 3rd party company to inflate their "oversize" count to justify their service. There is no incentive for them to be accurate. If they don't find any, UPS discountines the service. But if they "find" lots, then they justify their charges to UPS. We weight and measure every pkg. I might be off a pound due to scale differences, and I round down if it's under 1/2", ie 14-1/4 goes in as 14 but 14-3/4 goes to 15. On average we can't be more than 1" total of all three sides on any pkg.
Dannyboy.. "who sold us on this service?" I didn't know we had a choice. I do not recall signing up for someone to measure each of our pkgs and overbill us for some.

How do I get off this plan?
24into11 & barnyard.... I am mostly a very patient person. Partly due to my nature, but also due to the fact that we have a business to run and I spend most of my time running it. This issue keeps popping up... so I fire off an email or make a phone call and then "delegate it." The problem is this time that has not worked. Also we were with DHL before UPS and I waited 2 years with them to get us a printer and software. (They never did, which was one of the reasons we switched to UPS. As it turns out, that was a good idea.

Also shows you why DHL is no longer in business domestically.)
On the issue of "hundred weight" or whatever you call it. Here is a true story. One of our vendors always ships us UPS. So I told him to put it on our account. So he sent us an order. We get the UPS bill. $404! We previously put in the same order and he only charged us $245 for shipping. When I asked the shipper about it he said he was only charged $245 for the prev. shipment. So why then was I charged $404? As it turns out, he has the 100 weight deal and we did not. (Still don't.) I know I could have had this shipped via truck for about $165-$185 because we get pallets in all the time from CA and that's all we pay. Back long ago I used to ship books and there was a deal from UPS (or it might have been Fedex....) but if you had multiple boxes going to the same address on the same invoice, you got a good discount. Good enough that it competed with LTL on most large orders. Whatever happened to that?
To everyone I really want to thank you. It's been very helpful to find several sets of ears open.

I really hope next week gets this resolved.