Top 4 Common Manufacturing Problems That Can Crush Your Revenue

Article contribution by Jeremy Axel

Manufacturing problems are a common occurrence in the business world. Your product can be delayed or damaged, or you can suffer from production shortages. Your supplier and manufacturer have a responsibility to uphold, but they might not always live up to it.

Manufacturers have to deal with a range of problems that can damage the quality of their output. These five issues, even if they don’t cause complete product failure, can lead to lower sales and a poor reputation for the manufacturer.

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Product Failure

Product failure occurs when a piece of equipment breaks down or fails while still in the production line. As a result, the final product is significantly damaged and must be thrown out due to safety concerns.

Human error is one of the main reasons for product failure. Things like not setting a machine correctly or using incorrect technique to place parts can cause product failures. Production line equipment can break down and stop working with no prior warning.

Product failure is a common issue in the manufacturing industry. While this issue may seem to stem from sloppy workers or equipment malfunctions, it could actually be an indication of a deeper industrial problem.

Equipment failure

Occurs when a piece of equipment breaks down or fails while still in the production line. As a result, the final product is significantly damaged and must be thrown out due to safety concerns. This is also known as a “scrap rate.” When equipment malfunctions, it’s best to stop production right away so no more products are created with faulty or missing parts.

Equipment damage can be one of the most costly mishaps that can occur, especially when production has been interrupted due to a broken machine. If you have experienced this problem, then you can understand how costly it is to have a piece of machinery breakdown. A damaged conveyor belt, for example, could put a stop to your production line if it happens on a big scale. On the other hand, a piece of machinery could also develop a defect or need general maintenance. This would also disrupt your line and may require you to pay for new parts or even the company’s labor rates for the repair process.

For example, when your conveyor belt stops functioning, you will begin to notice a build up of products waiting to be sent out. At first this may not seem like a huge issue, but it can quickly snowball into being a major problem. Run a quick check by looking at the belts. If they appear to be loose, or if there are any missing, your motor might be failing or faulty. If this is the case, then you will need to replace the motor as well as any belts that are worn or missing. You can also read this article if you need to know how to make a proper replacement conveyor belt.

Poor Product Quality Control

Product quality issues can occur when there is inadequate control over various processes in production. Parts and materials may be defective or inconsistent, which will affect a product’s performance or durability.

When manufacturing products, it is important to have adequate quality control in place so that any issues with parts and materials can be identified quickly and resolved before they affect the product’s performance or durability. Quality control issues are common when there is inadequate control over various processes in production. Parts and materials may be defective or inconsistent, which will affect a product’s performance or durability. Quality control checks should be built into each step of a process, including incoming materials, manufacturing processes, assembly processes, product testing and shipping activities.

To maintain a strong quality management system, it is important to continually monitor for defects or inconsistencies at each step of the manufacturing process to identify potential problems early on. Regular audits should also be carried out by supervisors to check for any deviations from established standard operating procedures (SOPs) or policies. By implementing quality management systems that emphasize continual improvement, companies can minimize the risk of costly recalls or delivery delays due to defective products.

Poor Inventory Control

Poor inventory control can lead to wasted time and money on products that are not sold and subsequently have to be discarded. In some cases, manufacturers are forced to dispose of products for safety reasons in order to avoid liability for faulty products that have already been shipped.

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Types of common inventory problems include:

Inaccurate forecasting. Even small errors in forecasting can add up over time, leading to a surplus of unwanted products or shortages of popular products. For example, if you estimate that it will take two weeks to sell a certain product but it actually takes only one, you might end up with a surplus of the item in your hands. Similarly, if you overestimate the number of units that will be purchased by your customers, you could run out before you are able to replenish your stock.

Poorly organized warehouse space. Poorly organized warehouse space makes it difficult for employees to locate items quickly and accurately. This can result in lost sales as frustrated customers leave without making purchases. It is also frustrating for employees who have difficulty finding what they need when they need it. In addition, poor organization makes it difficult to place new products in the appropriate areas, potentially resulting in more waste and lost revenue due to incorrect placement.

Poor communication between departments: Communication breakdowns between purchasing and warehousing departments may result in the production or purchase loss.

Purchasing and warehousing departments do not communicate with each other, causing production or purchase losses. If the product is produced without the purchase order, you will have to throw it away and incur a loss. On the other hand, if the purchase is made without a production order, you may end up with an excess inventory.

Theft: Theft within manufacturing facilities is a common problem that results in not only monetary loss but also serious decline in revenue. Such losses are often caused by employees who steal directly from their own company, or by people who bring in outside parties to do so on their behalf.


It’s crucial for manufacturers to be aware of any potential quality issues they may have, in order to ensure they make high-quality products. Otherwise, they will end up losing money on product returns and low sales. In our list of manufacturing problems, we discussed many of the problems that manufacturers can face when they are attempting to get their products to market.

Manufacturers have to deal with a wide variety of potential issues that could affect what they produce and how they ultimately present their product or service to the world. No product or service will be perfect, but there are steps that these businesses can take to reduce these sorts of problems and make sure their customers continue buying from them for years to come.

About the Author Jeremy Axel

Jeremy Axel is the founder of Fluent Conveyors, they design and manufacture conveyors for Waste and recycling industries, Manufacturing, and Distribution centers across the United States. He is also known for building trusted relationships with conveyor dealers and reseller networks and developing advanced technological processes and tools that help them do their jobs more efficiently.