Manufacturing Process Management: Over 50% of Errors Discovered at Fatal Stages 'After Spec Confirmation/Delivery'. Annual Opportunity Loss from Management Errors Reaches ~1.23 Million Yen
Ingage Inc. released a survey revealing that 52.4% of task management errors in the manufacturing industry are discovered at critical stages such as after specification confirmation. The disconnect between email communication and Excel management causes an annual opportunity loss of approximately 1.23 million yen per company.
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- 📰 Published: April 6, 2026 at 19:00
- 🔍 Collected: April 6, 2026 at 10:31
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Ingage Inc. (Headquarters: Osaka City, Osaka Prefecture; President and CEO: Tetsuya Wada; hereafter "Ingage"), which provides the communication platform "Re:lation" with a track record of over 6,000 corporate adoptions (*1), has conducted a survey on the "Realities of Process Management" targeting business professionals working in the manufacturing industry.
◆ Industry Challenges
In manufacturing sites, it is common for "specification adjustments (via email)" with clients and partner companies to be operated separately from internal "process management sheets (like Excel)." However, this disconnection between tools goes beyond mere administrative inconvenience. It is a structural management issue that causes omissions in data transfer and delays in confirmation, increasing "rework" on the shop floor and "confirmation costs" for managers.
◆ Survey Results
1. Over Half of Errors Discovered at the Fatal "Point of No Return" Phase
The timing at which task omissions and misunderstandings are discovered in the manufacturing industry is concentrated at fatal stages: "after specifications are confirmed or right before contract (43.4%)" and even "after delivery/completion (9.0%)," totaling 52.4%—more than half. This exceeds the all-industry average (48.8%), highlighting a vulnerability specific to the manufacturing industry where the later an error is discovered in the process, the more the rework costs skyrocket.
2. Opportunity Loss Reaches "Approximately 1.23 Million Yen Annually," 1.3 Times the All-Industry Average
When these inefficiencies and errors caused by dual management are converted into monetary value, the annual opportunity loss in the manufacturing industry (sales that should have been gained or wasted labor costs) averages "approximately 1.23 million yen." This result, which is 1.3 times the all-industry average (approx. 936,000 yen), proves that the fragmentation of information at manufacturing sites directly chips away at corporate profits.
3. About 60% Lose Time to the Double Effort of "Searching Emails"
In the manufacturing industry, 57.8% of respondents end up redoing work by "checking with subordinates" or "searching emails" because detailed context remains unclear even when looking at the management sheet. Furthermore, moving from emails to management sheets/tools creates constant friction.
◆ Industry Challenges
In manufacturing sites, it is common for "specification adjustments (via email)" with clients and partner companies to be operated separately from internal "process management sheets (like Excel)." However, this disconnection between tools goes beyond mere administrative inconvenience. It is a structural management issue that causes omissions in data transfer and delays in confirmation, increasing "rework" on the shop floor and "confirmation costs" for managers.
◆ Survey Results
1. Over Half of Errors Discovered at the Fatal "Point of No Return" Phase
The timing at which task omissions and misunderstandings are discovered in the manufacturing industry is concentrated at fatal stages: "after specifications are confirmed or right before contract (43.4%)" and even "after delivery/completion (9.0%)," totaling 52.4%—more than half. This exceeds the all-industry average (48.8%), highlighting a vulnerability specific to the manufacturing industry where the later an error is discovered in the process, the more the rework costs skyrocket.
2. Opportunity Loss Reaches "Approximately 1.23 Million Yen Annually," 1.3 Times the All-Industry Average
When these inefficiencies and errors caused by dual management are converted into monetary value, the annual opportunity loss in the manufacturing industry (sales that should have been gained or wasted labor costs) averages "approximately 1.23 million yen." This result, which is 1.3 times the all-industry average (approx. 936,000 yen), proves that the fragmentation of information at manufacturing sites directly chips away at corporate profits.
3. About 60% Lose Time to the Double Effort of "Searching Emails"
In the manufacturing industry, 57.8% of respondents end up redoing work by "checking with subordinates" or "searching emails" because detailed context remains unclear even when looking at the management sheet. Furthermore, moving from emails to management sheets/tools creates constant friction.