Supply chain headaches are profit killers. From late shipments to inventory chaos, these problems snowball fast. The good news? You can solve most of them without hiring a consultant or buying new software—just by doing a few simple things differently.
There’s a reason supply chain issues frustrate so many manufacturing business owners—it’s rarely just one problem. One delay leads to another, and suddenly you’ve got idle machines, overtime pay, and angry customers. But most of these issues are predictable. And once you see the patterns, the fixes become pretty straightforward. Let’s walk through five of the most common supply chain headaches—and some practical ways to fix each one fast.
1. Raw Material Delays That Leave Machines Idle
If you’ve ever had to push out a production run because a truck didn’t show up with a shipment of raw materials, you already know the cost isn’t just lost time. It’s labor sitting idle, machines going unused, and rescheduled deliveries to your customers. And if this happens more than once, your clients start to wonder if you can keep up.
One major issue is relying too heavily on a single supplier without a backup plan. A lot of businesses do this because it’s easier to manage one relationship. But when that supplier has a hiccup, you’ve got no safety net. That’s why smart manufacturers set up secondary vendors in advance. Not for everything—just for the core items that would shut down production if delayed even a day.
Here’s a good example. A machine shop that makes parts for heavy equipment used to get 90% of its steel from one vendor. When that vendor had a breakdown at their mill, orders were stuck for two weeks. After that, the shop spent a month identifying two additional steel suppliers in nearby states. Now, when delays happen, they can pivot quickly—and they no longer have to eat rush fees or delay customer orders.
You don’t need to carry six months of extra stock, but you do need a buffer. Keep enough inventory on hand to absorb small disruptions, especially for fast-moving parts. And if you’re buying internationally, consider sourcing some critical materials closer to home—even if it’s a bit more expensive—because the predictability is worth it. You’ll sleep better knowing you’re not one truck delay away from grinding to a halt.
2. When You’re Blind to What’s Actually Going On
One of the biggest problems isn’t what’s late—it’s not knowing what’s late until it’s too late. Too many manufacturing businesses are making critical decisions with disconnected data. One team has supplier info in email, another is tracking deliveries on paper, and production is guessing based on what’s on the floor. That kind of setup guarantees mistakes, missed purchase orders, and late jobs.
You don’t need a fancy ERP to fix this. You just need one place where your team can see the essentials: what’s been ordered, what’s expected, what’s delayed, and what’s in stock. One business I know—a plastics manufacturer—solved this using a shared Google Sheet. It tracked every PO, expected delivery dates, supplier contact info, and who was responsible for follow-up. Everyone from the office manager to the shop floor could access it. Within a month, they cut confusion, sped up problem-solving, and dramatically reduced “I didn’t know” moments.
The real fix is visibility. If your team can see what’s happening in real time, they’ll start catching problems before they blow up. That alone can eliminate half the last-minute scrambling you’re probably dealing with today.
3. Inventory That’s Either Too Much or Not Enough
Inventory is like a thermostat—too low and you can’t produce, too high and you burn cash. The worst part? Most manufacturers are stuck in a cycle of guessing. You get burned by running out of stock, so you overcorrect and buy too much. Then you’re stuck with slow-moving material and less room in your shop.
One simple change is switching to a rolling 90-day reorder model. Instead of ordering based on last quarter’s usage, review your sales and demand trends every two weeks and update your reorder quantities accordingly. A fabrication business that serves multiple industries made this change and started catching shifts in demand much faster. For example, when one of their customers suddenly pulled back on orders, they adjusted inventory levels that same week—saving nearly $20,000 in unneeded materials.
Also, look at which items really need to be reordered frequently. Don’t try to manage everything manually—just focus on your high-volume, high-margin parts. If you automate anything, start there. The goal isn’t perfection. The goal is to stay close enough to real demand that you’re not constantly overreacting.
4. Weak Supplier Communication That Breaks Down When It Matters Most
Many supply chain problems come down to bad—or zero—communication. Most manufacturers only call their suppliers when something is already going wrong. By then, it’s too late to fix it without drama, extra cost, or unhappy customers.
Here’s a better approach: treat your top suppliers like partners, not vendors. Set up a 15-minute monthly call with your top 3 to 5 vendors. Not to check in casually, but to talk through changes in forecasts, potential delays, or anything they need from you. One business that makes packaging products started doing this and quickly found that even just a heads-up about order shifts helped their supplier plan ahead and hit deadlines more consistently.
Relationships still matter in manufacturing. When your suppliers know you’re proactive and respectful of their time, they’re more likely to give you the same in return. And when you do hit a snag, they’ll be more willing to prioritize you over someone who only shows up to complain.
5. Freight Surprises That Blow Up Your Budget
Freight is one of those things that always seems to cost more than expected—especially when it’s arranged at the last minute. It’s easy to rely on freight brokers for convenience, but that convenience comes at a price. If you’re scrambling to get something shipped today, you’re probably overpaying by 25% or more.
The smart play here is to build relationships with 2–3 local or regional carriers and negotiate fixed pricing in advance. You don’t need 10 options—just a few reliable ones who know your business and can deliver without drama. One custom parts business that did this cut their monthly freight spend by $5,000 and improved delivery performance to customers by over 90%.
Also, use basic shipment tracking tools. Even simple platforms like FreightPOP or ShipStation give you a better view of what’s inbound or outbound. When you know what’s arriving, where it is, and who’s handling it, you can plan better—and avoid having to pay someone extra to fix a surprise later.
Top 5 Supply Chain FAQs Manufacturing Owners Ask
1. What’s the easiest first step to get more supply chain visibility without buying software?
Start with a shared spreadsheet that tracks POs, inventory levels, and delivery dates. Keep it simple and updated daily. Everyone should be able to view it in one place.
2. How do I build backup suppliers without overcomplicating things?
Focus only on your most critical materials first. Identify two alternatives for those items and start small orders or trials now—not when you’re already in a crisis.
3. How much buffer inventory should I keep?
Enough to cover your average supplier delay plus a few days of cushion. This is different for every business, but one to two weeks of extra supply for high-risk inputs is a good rule of thumb.
4. How often should I review inventory reorder levels?
Every two weeks. The more often you review and adjust, the faster you can respond to real demand shifts. This helps avoid both shortages and overstock.
5. How can I get suppliers to improve without damaging the relationship?
Start with data. Track their performance, then share it with them during monthly calls. Frame it as “here’s how we can get better together” rather than pointing fingers.
Don’t Wait for the Next Supply Chain Fire
Most of the fixes that work don’t require big budgets or new systems. They require better habits, clearer visibility, and stronger relationships. Start by picking one headache from this list and fixing it this week. The faster you move from reacting to preventing, the more control—and margin—you’ll get back.