Ok, got back from the feed store today with a fount of information.  Several possibilities...
1.  Lazy birds - mix the shell with the feed for a while in addition to the free choice dish.
2.  A very experience chicken raiser recommended 18% layer feed for the best results.  Well, I couldn't find it so I mixed 18% unmedicated chick starter with 16% layer crumbles for the last 100 pounds of feed.  So, perhaps the chick feed is deficient enough in calcium to make a difference even when mixed with layer crumbles and free choice oyster.
3.  Too MUCH free ranging and not enough protein.   Leave them in the coop a little longer in the morning.
I've made some modifications along with purchasing the 18% crumbles from the feed store instead of the local farm and barn store.  We'll see if it makes a difference.