Grattman,
I think (99% sure) this is a Windows issue. Any tinkering with profiles causes the Windows PCs to think the newly created profile is the "wrong" one, so it creates a new profile and does not use the roaming profile.
To check, using Windows XP: Right click My Computer, choose Properties, then Advanced, then User profiles.
If you see an entry something like this in the user profiles (for user "fred")
fred 21Mb roaming
fred.000 156Kb local
- then that is your problem. User "fred" is getting the "fred.000" profile when they log on.
If so, I suggest you look to Windows Forums for help with the issue.
Someone else here may be able to help you, but I really think it is Windows not SME
As another issue, do you NEED roaming profiles? Best avoided if you can - especially if people don't actually "roam" from desk to desk.
Cheers - and good luck
Ian