Are you pressing your seams open or to one side? Are your seams meeting right at the edge of where the dog ears are cut off? I love the Accuquilt system and these are two of the most common problems. I discovered a long time ago that their 1/4" was not my 1/4" now I have it mastered and most everything will lay flat I also use a wool cutting matt. This can make a big difference. You should not have to square up the block as they are designed to be a perfect match to each other. If I do manage to get off I don't worry to much as the blocks are designed to match. I know that by the time I bat and back the quilt and then quilt it is going to be perfect!