Contact Management - Best practices for couples and households
We have been going over this a lot with my fundraising team, trying to find a happy medium. When generating labels or PDF letters for one per household, be sure to create labels with only households. Then, you can even create a smart group that consists of individuals that are also part of a household and exclude that group from the rest of the "individuals" mailing list so that you don't get labels with both households and the same people individually. 

Every time someone proofs the labels for duplicate members of the household, they should mark it up and have someone change the data in the CRM to add them to a household.