Illustrator CS4 compare type size to actual

When I set the type size from the drop down box it measures on the screen and prints out smaller than the size I want. ie 50mm type is 34mm actual, the bounding box however is the type size 50mm. As a sign writer this causes a problem as customers order type of a particular size and when printed it is much smaller. I appreciate that I can create outlines and enlarge the size accordingly however I would have expected the type size to be the same as in the drop down type box.
thanks Andrew

You might want to take a look at my AI Javascript script named JET_SetCapHeight.jsx, which can be downloaded
here
JET

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