About 99% of the orders coming in are "offline" shipping. Does this have something to do with the new flat rate system? If we forget to select shipping during processing (and sometimes we do, we get busy), we then have to create a label in UPS....hugely time consuming.
When you have flat rate shipping, checkout has to use a separate designation for the shipping method as it is not related to UPS rates. Thus, it will default to the "No Label" option. If you do want to ship UPS, then you must remember to choose the appropriate method when processing your order.
Many of our clients use the flat rate because they want to use another shipper and do not want a UPS label.