3 Common Order Mistakes That Crush Margins (and How to Avoid Them)

Whether you’re a distributor, agency, merch brand, or internal marketing team, order prep is the make or break of your margins.
And we’ve seen it all.

After processing thousands of orders at ReSourceUSA, we can tell you that the fastest way to lose time, lose money, and lose your mind is simple:

👉 Submitting an order with missing, unclear, or inconsistent details.

But here’s the good news:
Every one of these problems is preventable.

Today we’re breaking down the 3 most common mistakes that cost companies real money and how you can avoid them so your orders flow smoother, faster, and more profitably.

Mistake #1: PO & Art Mismatch

(The #1 Cause of Production Delays in Contract Printing Industry-wide.)

Ask any screen-printing operation why jobs get delayed, and they’ll tell you the same thing:

The PO says one thing. The artwork says another. The email says something completely different.

When the details don’t line up, production can’t begin.

Examples we see all the time:

• PO says 1-color; art file shows 3-color

• PO asks for full front; art is sized for left chest

• Artwork shows brand colors; PO lists Pantone substitutes

• The email says “same as last time”… but the last time wasn’t clear either

• PO lists 144 pieces; boxes arrive with 137
  
  

Every mismatch forces a time-sucking chain reaction:

• admin clarification

• client email

• waiting for corrections

• rescheduling the job

• re-burning screens

• holding up the press
  
  

How to Avoid It

• Treat the PO as the official truth

• Ensure artwork updates are reflected in the PO before you submit

• Always list print size, placement, colors, and location clearly

• Match your quantities to the boxes you ship no guessing
  
  

Want an even faster fix?

Ask us for our PO Submission Checklist and we'll send it your way.

Mistake #2: Shipping Blanks Without a Packing List or Box Count

(The fastest way to guarantee delays before your order even gets unboxed.)

When blanks arrive at our dock without:

• a packing list

• box count

• size breakdown

• PO number

• indication of what belongs to what job

…it slows everything down.

We can’t verify without information.
And if we can’t verify, the order can’t move to production.

Here’s why this matters:
Receiving accuracy protects YOU.

It ensures your blanks are counted correctly, your shortages are caught, and no surprises pop up at the press.

How to Avoid It

Include this every time:

• PO Number

• Total Box Count

• Breakdown by size & style

• Which buyer/order the blanks belong to

• “ATTN: ReSourceUSA Receiving” on the label
  
  

Your receiving process becomes seamless and your jobs move faster.

Mistake #3: Last-Minute Rush Orders Without Clear Timelines

(Rush jobs aren’t the problem — unclear rush jobs are.)

We’re built to move fast.
We love a good challenge.
But “We need this ASAP” doesn’t mean anything without context.

Are you asking for:

• 24 hours?

• 3 days?

• by Friday’s event?

• before the client’s launch?
  
  

Unclear timelines create:

• production disruptions

• rescheduling

• wasted screens

• delayed jobs for everyone else

• margin loss for YOU when it triggers fees or mistakes
  
  

How to Avoid It

When requesting a rush job, always include:

• Exact due date

• Ship-by date

• Whether shipping overnight is acceptable

• Whether substitutions are allowed

• If partial shipments are acceptable

• Whether artwork is FINAL (no changes allowed)
  
  

Fast becomes easy when details are clear.

Why These Mistakes Matter (and How We Help Prevent Them)

Every mistake above has one thing in common:

👉 They cost time, money, and margin for you and your client even if you never see the breakdown.

At ReSourceUSA, we’ve built our workflow to eliminate as many of these issues as possible before they snowball:

• receiving verification

• PO review

• pre-production checks

• mandatory press counts

• communication back to you immediately if something’s off

• QC at multiple checkpoints

• finishing and packing standards that prevent surprises
  
  

We don’t just fulfill orders, we protect your bottom line.

Want Fewer Surprises and More Smooth, Profitable Orders?

Let us help you fix your order workflow before it hits production.

We offer:

• FREE workflow reviews

• PO submission checklist

• Art & spec alignment recommendations

• Pre-production best practices

• Recommendations to help your internal teams avoid bottlenecks
  
  

Your jobs don’t have to be stressful.
Your orders don’t have to bounce around.
And your margins don’t have to take unnecessary hits.

ReSourceUSA is here to make sure they don’t.

Email: vickie@re-sourceusa.com
Book a call: https://calendly.com/vickie-re-sourceusa/contract-apparel

— The ReSourceUSA Team

(A.K.A. the people behind your print… and your peace of mind.)