Printing Is a Critical Part of the Supply Chain

The Manufacturers Outlook Survey for Q1 2026, conducted by the National Association of Manufacturers, presents an optimistic outlook among manufacturers in all industries. In particular, production output is set to increase 3.5%. This upswing is largely due to manufacturing operations evolving into a smart manufacturing ecosystem, which involves modernized technology, connectivity, and automation getting built into equipment and processes from the ground up.

Manufacturing organizations have been actively pursuing smart manufacturing for the past few years. A 2025 Deloitte survey of 600 manufacturing executives revealed that 78% planned to invest 20% or more in smart manufacturing initiatives, with a focus on foundational tools and technologies. Examples include automation hardware, data analytics, sensors, and cloud computing. According to the survey results, smart manufacturing is viewed as the impetus for improved production output, increased employee productivity, and expanded capacity. Much of the credit for these improvements goes to technologies such as artificial intelligence (AI), digital twins, and edge computing.

While a company’s supply chain is a central component of the manufacturing operation, it is an entity long hampered by inefficient processes, siloed functions, labor-intensive production, and slow responsiveness to change. This paradigm has largely been justified by the phrase, “That’s just the nature of supply chains.” However, these conditions can have far-reaching effects, including rising costs, declining sales, missed deadlines, and strained customer relationships.

Fortunately, through advanced technology, supply chains have become a proactive, autonomous, and adaptive ecosystem. Essentially, they have become intelligent supply chain systems that harness AI, big data, IoT, and edge computing to enable seamless connectivity and data exchange, improving visibility, streamlining operations, and enabling real-time decision-making. These intelligent supply chains dynamically adapt in response to up-to-date data, supplier availability, and even global disruptions. 

Manufacturers produce a surplus of printed documents, including order forms, compliance reports, product and shipping labels and barcodes, bill of materials, etc. In manufacturing, inefficient printing processes can cause costly disruptions, affecting multiple phases of the supply chain, including inventory management, production, and delivery timelines. This type of unplanned downtime remains one of the most expensive disruptions in manufacturing.

The Impact of Manufacturing Downtime

According to data gathered on manufacturing downtime:

• 30 hours is the average amount of downtime manufacturers experience monthly.

• 60% of manufacturers reported losing over $250,000 annually due to unplanned downtime.

• 2 hours of unplanned downtime can cost up to $1,400.

When the necessary documents and labels cannot be printed, downstream supply chain issues and costs multiply:

• Products cannot be delivered.

• Production stops until the company can restore printer functions.

• Some industries are charged late delivery penalties, which can range from $1,000-$50,000 per incident.

Why Are Items Not Printing?

Unstable Print Spooler

Instead of sending print jobs to a printer, the PC sends them to a print spooler, which holds them in a queue and releases them one by one to prevent a system overload. When documents don’t print, the spooler is often the culprit. Spooler malfunctions are often caused by:

• Corrupted files. A corrupted file will not print, which stalls all the other print jobs in the queue.

• Outdated or too many printer drivers. Drivers consume resources. Even after they are uninstalled, printer drivers can still leave monitoring services running, which take up more resources.

• System updates. Applications, operating systems, and print servers are frequently updated to incorporate the latest bug fixes and enhancements. The updates may cause incompatibility or connectivity issues, or simply take a long time to complete.

• Malware. Malware can cause a variety of problems that can interfere with printing, including overloading the print server, corrupting files, and launching multiple instances of spoolsv.exe (Print Spooler Service). Windows is designed to run only one instance of the Print Spooler service. If multiple instances are running, it could be due to a virus or Trojan infection.

Network Connectivity Failures

Networked printers rely on a stable connection among the printer's network adapter, the Wi-Fi, and the device that sends the job. When any part of that chain falters, due to a weak signal, microwaves, or system overload, printing will shut down. It will require IT assistance because the issue likely extends beyond the printer.

GPO/Script‑Based Printer Deployments Causing Server Overload

A Group Policy Object (GPO) is a feature in Windows Server that can be implemented in the Active Directory, allowing system administrators to control aspects of the user or service environment within the network from a global perspective. However, GPOs can create challenges that lead to significant printer bottlenecks and downtime, impacting the entire organization. Common GPO issues include incorrect permissions, driver conflicts, and improperly configured point-and-print restrictions.

Manufacturers are under pressure to improve production efficiency and achieve faster turnaround times. As supply chains continue to evolve, printing will play an increasingly strategic role. Labeling is no longer a simple print-and-apply task. It’s becoming a dynamic, data-driven layer of the supply chain. Product labels and all packaging and delivery documents must be clear, accurate, and on schedule. Also, workers on the warehouse floor want immediacy and simplicity. They want to scan an item with a mobile device and print the corresponding label on the spot, without any delays or middle steps. That said, businesses need to implement flexible, high-quality printing solutions to quickly respond to operational challenges, reduce lead times, improve coordination, and enhance operations.

Traditional print infrastructures are outdated systems with too many different components to rely on for printers to function properly.

• Print Servers. Dedicated machines (physical or virtual) that manage all print jobs within a network. They receive requests from client devices, add them to a queue, and send them to the appropriate printer. It’s common for large organizations to deploy multiple print servers (often one per site or floor) to handle load and reduce network latency.

• Printer Drivers. Software packages that are installed on each client device that translate print commands into a language the printer understands (such as PCL or PostScript). Each printer model typically requires its own driver. To work properly, drivers must match both the operating system and printer firmware version.

• Print Queues. Each printer is represented as a queue on the server. When users submit print jobs, they are held in the queue and released in an order managed by the print server.

Over time, IT teams have bolted on new servers, custom integrations, and temporary fixes to keep things printing. At some point, organizations can no longer rely on patches and workarounds. The foundation itself needs an upgrade of all the system parts.

For years, print servers and traditional output management tools held things together. But now, they’re struggling to keep up with the pace of digital transformation. Server outages, scaling challenges, and endless troubleshooting are making it difficult for IT teams to keep up with the demands of overseeing these systems. They are constantly addressing the same recurring issues: crashes, bottlenecks, failed deployments, and security vulnerabilities.

Printing functions have primarily moved to serverless infrastructure, eliminating the need for traditional print servers. Users can install printers without IT intervention, and send print jobs directly to them without relying on servers and drivers. Also, removing print servers means a single admin can handle all printer and user requirements from a single console.

AI Capabilities: A New Level of Digital Transformation

Artificial intelligence (AI) is embedded in our daily work. Across industries and company sizes, it’s changing how information is captured, processed, shared, and secured. The role of AI in manufacturing printing is expected to continue growing, offering even more intelligent and interconnected capabilities. According to the Quocirca Ten Key Trends for 2025:

• 84% of organizations planned to increase expenditure on AI

• 79% planned to upgrade to AI PCs

• 73% planned to refresh their print infrastructure

The organizations that have or are implementing AI are recognizing significant benefits, such as less downtime, reduced costs, stronger security, and more efficient printing. The following are processes that companies commonly complete with their AI technology:

• Predictive maintenance and supply management. AI continuously monitors device health, such as toner levels, drum wear, paper jams, and usage patterns, and predicts failures before they occur. This reduces unplanned downtime and allows proactive servicing rather than reactive break/fix calls.

• Intelligent print job optimization. AI identifies usage patterns and optimizes print queues by forecasting peak printing periods, scheduling non‑urgent jobs during low-demand times, and prioritizing jobs based on urgency or user role.

• Automated driver and fleet management. AI handles driver deployment and updates centrally and can analyze a device fleet based on actual usage data to recommend consolidating or redeploying underutilized hardware.

• Security and threat detection. AI monitors the print environment as part of the broader network security posture. It can detect unusual behavior, enforce Zero Trust authentication (PIN release, badge tap, or biometric), and flag potential data issues via the print channel.

• Print automation. Printers can pull live data from an MES or ERP system, apply it to the correct label template, and trigger printing without human intervention. This ensures that every label, printed on the shop floor, at the packaging station, or in the warehouse, is timely, accurate, and compliant.

Intelligent Print Automation (IPA) enables companies to consolidate, digitize, modernize, and automate end-user and critical print processes through controlled document workflows. IPA bridges traditional print management with modern digital transformation. The functionality unifies end-user and critical systems printing on a single cloud-native platform, enabling organizations to actively optimize all print systems and functions.

Set up a robust, seamless, and reliable printing infrastructure and reimagine your enterprise where technology and innovation fosters industry leadership. Schedule a demo with PrinterLogic today to see how modern printing can transform your business.