Normally this would not be an issue if say the difference was 4 or 5 but it is adding 68 pixels to the height and width when triggered through a process for this form.
In the building of a form it is impossible to tell what the form will look like rendered through the front end even using the preview functionality. You have to test and lock it multiple times to get the precise dimensions, add to that the difference in size when the same form is triggered through different mechanisms and you are almost forced to have multiple forms for each triggering mechanism.
Looking closer at the issue it appears that when the form is originally built the dimensions are the entire form including the buttons (Save/Create, Cancel). Then when the form is triggered from a process the buttons are not part of the consideration and the form is rendered with the internal dimension specified. Just a though as to what could possibly be causing this difference. I could be wrong.