June 3, 2023

5 Common Manufacturing Problems – And How To Avoid Them

  • April 22, 2022
  • 6 min read
5 Common Manufacturing Problems – And How To Avoid Them

Whether you’re a startup or an established company, it’s important to be aware of common manufacturing mistakes so that you can avoid these pitfalls. Rushing into production on a product without fully testing it or making sure all the pieces are in place will lead to delays, last-minute changes, and disappointing customers with inferior products.

There are many pitfalls to manufacturing a product and releasing it to the public. From the problems that can arise in the design phase, to the manufacturing process itself, to shipping and handling, there are plenty of ways for things to go wrong. If you’re launching a new product or even just thinking about it, it’s worth taking some time upfront to identify potential problems you may encounter and discuss solutions with your suppliers so that you can avoid any issues when they come up.

Here are five problems that have been identified by manufacturers and other industry professionals:

Ineffective Production Software

As businesses grow and change, so do their needs when it comes to production software. A growing business will need a powerful tool that can accommodate an expanding workforce, while a business in a state of transition may need something that can help smooth over the bumps of restructuring. Ineffective production software is a problem for many companies: they want a tool that can manage all aspects of their workflow but find themselves spending too much on maintenance or upgrades.

If the software used in production is not optimized for the product being made. This could result in incorrect documentation or even hardware malfunctions that cause the products to be scrapped or thrown out before they can be sold. It’s crucial to have the right software at every stage of development and production so that each step of the process is accounted for.

A few common problems with production software include:

-Lack of customization. Using a cookie-cutter system that doesn’t fit your business model or industry could lead to wasted time and effort on both sides. You need software that can adapt to your specific needs without being overly complicated.

-Lack of accountability. When everyone on staff has access to all of the information, it can be hard to pinpoint where the problems are coming from. You want software that allows you to see exactly who accessed which data when they did it, and what changes were made. This will help you pinpoint issues and solve problems faster than ever before.

-Lack of security. Data theft is a big risk in today’s digital world. If hackers get their hands on your information, they could do serious damage to your business—and there may not be much you can do about it

Faulty Machinery

The machines used to make your product aren’t well calibrated, which can cause them to skip steps or make mistakes

One of the most common problems that can occur when using machines is that they break down. This problem can range from being inconvenient to actually endangering people’s lives. A faulty conveyor can cause huge damage to your production lines and even halt your entire operation. This is why it’s important to have conveyors that are designed to run smoothly and efficiently. Contact conveyor manufacturers near me if you need to urgently replace your equipment.

You can avoid dealing with faulty machinery is to test your machine before using it. Make sure it works properly, and if you’re using it for a specific project, make sure that it’s capable of doing the job you need it to do. You can check this by taking the machine through its paces, making sure all parts work as they should and all mechanisms move correctly.

Another way to avoid faulty machinery is by checking your raw materials before manufacturing starts. Any holes in the material or flaws in the material will cause problems when the final product is made, so make sure there aren’t any before you begin manufacturing. A good way to do this is by inspecting every batch of raw materials you receive before beginning production. If there are any holes or flaws, reject the entire batch, even if only one piece has a problem. It’s better to be safe than sorry and lose money on defective products later on due to a single mistake during production.

Storage Issues

Another usual problem for manufacturers is a lack of storage space. This can result in the need to store items outdoors, which can cause them to deteriorate over time, or turn around and incur additional fees.

Even with the right space, storage can be a problem. In fact, for many businesses, storage is their biggest problem. If a part or raw material has to sit in storage for too long it can become damaged or obsolete.

Implementing warehouse management software (WMS) will help you manage your inventory and improve your forecasting. Not only that, but it will also give you a better understanding of what’s on hand, what’s in order and what’s available at any given time. A good WMS will integrate with all systems to keep your entire inventory streamlined, getting rid of the need for duplicate data entry and paperwork.

In some cases, the solution is simple: Either order more raw materials in smaller quantities or make sure your employees are keeping track of what they have and what they need. If you have an inventory system in place, you can avoid having an overstock of any one item while also avoiding a shortfall when you need something.

Poor Quality Control

Poor quality control is the leading cause of poor quality products. In order to achieve the best results, you first need to know the common problems that occur in manufacturing. This will help you correct any mistakes before they get made, and it will make your company more profitable by preventing unnecessary losses.

Quality Control Tips:

  • Hire employees who are passionate and educated about their work
  • Limit stress on the supply chain by ordering only what you need
  • Test and evaluate products regularly to ensure manufacturing consistency
  • Use technology to automate testing procedures

Lack of Communication and Poor Customer service

Customer service is important during manufacturing and after an order is complete. Communication with your customer will also assist in building your business and generating repeat business. A lot of customer service goes beyond just answering questions about a particular order; it includes keeping people updated on the status of their order, as well as providing assistance on product selection and other information to help your customer make good purchasing decisions in the future. 

The Author Jeremy Axe


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. 


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