Ease.io Report Reveals Quality Gaps in Manufacturing

Survey of 1,000 manufacturing professionals reveals deep disconnects that could undermine safety, performance, and employee retention.

Ease, operating as Ease.io, a leader in audit and inspection software for manufacturers around the world, released a new research report, "Pulse on Quality: Are Leadership and Frontline Teams Aligned?" that unveils substantial gaps between leadership and the frontlines when it comes to quality management in manufacturing. The data, collected from an independent survey of 1,000 manufacturing professionals, shows notable differences in how quality is perceived between frontline operators and management including its value, implementation, and role in daily decision-making. There also is misalignment in their overall confidence in processes, people, and technology, including artificial intelligence (AI). The differences between the two groups are particularly concerning right now, when global economic uncertainties are putting many manufacturers in reactionary positions. "Manufacturers are under intense pressure right now to tighten budgets, but without shared understanding between the top floor and the plant floor, any change in strategy is risky," said Eric Stoop, CEO, Ease.io. "The consequences are especially acute when it comes to quality, because it can and will have downstream negative effects impacting safety, productivity, customer outcomes, and the bottom line." HR Technology Insights: Zoom, ServiceNow Partner to Enhance Customer, Employee Experience Compounding these implications is the persistent labor shortage that the industry continues to experience. According to the U.S. Bureau of Labor Statistics, there are currently nearly half a million U.S. manufacturing jobs that remain unfilled. "The data from Ease.io is a leading indicator that alignment is needed," said Daniel Castilla, founder of DPC Ollin.One Consulting and former head of quality at a Fortune 500 automotive manufacturer. "When people, especially those on the frontlines, are disengaged from their leaders' views, they're obviously much more likely to feel dissatisfied with the company strategy or even the industry and look for opportunities that better align with their views. Companies need to factor in not just the cost of replacing workers, but what it takes to train and build the knowledge that's required for specialized roles."

Key findings and data points include:

The Quality Culture Gap is Real

• A strong majority of managers (92%) view their company's quality culture favorably.
• But, 1 in 4 frontline workers don't believe or are unsure if their company has a positive quality culture.

Leadership is More Confident in Quality Management Versus Workers

• Nearly half (48%) of frontline workers lack a strong understanding of their company's quality management protocols.
• In contrast, 77% of managers said they understand "very well."
• The majority of frontline workers with less than 10 years of experience (54%) do not have a strong understanding of processes.

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Quality Issues are Often Overlooked

• Nearly half (49%) of frontline operators have experienced quality issues being ignored or covered up.
• Of the workers who saw issues, only half (51%) reported them to their manager; 1 in 4 didn't say anything at all.
• On the flipside, 98% of managers say their concerns about quality are followed up on.

Artificial Intelligence in Quality is Unequally Understood

• Operators are less familiar with AI than management believes: Half (50%) of managers say their teams understand AI well, but only 28% of operators say that of themselves.
• Overall, less than half of respondents (22% of operators, 43% of managers) say they or their company use AI for quality management.

The report also provides recommended actions that manufacturing leaders can take to close the gaps. "Our research is a wake-up call, but gaps in culture, confidence, and communication aren't unsolvable; they can be opportunities to build resilience," said Stoop. "Manufacturers that focus in these areas will be the ones who can outperform even in volatile times."

More Information

The full Ease.io 2025 research report, "Pulse on Quality: Are Leadership and Frontline Teams Aligned?" is now available for download. For the report, Ease.io commissioned an independent survey of 1,000 manufacturing professionals — 500 manufacturing frontline operators and 500 manufacturing managers — currently employed in the United States. The survey was fielded between February 21 and March 11, 2025. HR Technology Insights: Atento Brings AI to Customer & Employee Experience To participate in our interviews, please write to our HRTech Media Room at sudipto@intentamplify.com Source: PR Newswire