The hidden cost of expansion: why global manufacturers struggle to get it right

For manufacturers, making sure their content matches their audience isn’t a finishing touch — it’s the infrastructure that ensures global ambition translates into sustainable success.

Why global ambition doesn’t always equal global success – and the enabler every ambitious manufacturer needs 

Global manufacturing leaders share a common ambition: expand into new markets, scale operations, and capture growth where demand is rising. But too often, these ambitions collide with a hidden cost — the underestimated complexity of local markets. Regulations, supply chain realities, and cultural expectations can undo even the best-laid expansion strategies, turning growth plans into costly setbacks.

In Chapter 1 of this series (“Smart factories, smarter risks”), we explored how technology is transforming the sector. Here, we look at the other half of the equation: market fluency. For manufacturers, making sure their content matches their audience isn’t a finishing touch — it’s the infrastructure that ensures global ambition translates into sustainable success.

Global ambition meets local reality

Global manufacturing is increasingly recovering from recent economic and geopolitical shocks. Growth has returned to the sector, with many analysts predicting output growth of up to 5% over the next five years. But as always, this global pattern masks distinct regional trends: Europe is forecast for only moderate growth, and an increasingly developed China is expected to grow more slowly than we’ve seen in the past. On the other hand, emerging economies, particularly within Asia, are expected to perform much more strongly.

There are many reasons why established manufacturers may want to expand their operations into regions experiencing economic prosperity. Often, strong growth is fuelled by favourable conditions on the ground, such as tax breaks, low labor or land costs, or a good supply of skills. Equally, creating new plants in new territories makes it easier to satisfy regional demand, offering different products, built in factories that benefit from efficiencies in local supply chains and distribution.

But expanding into new territories is riddled with pitfalls. The same labor, land or regulatory differences that create strategic advantage, also present businesses with complexity. Core processes, training, instructions and policies will need not just translation, but careful adaptation for the regulatory and cultural environment in which the business now works. Brands are easily mismanaged, with core messaging that resonates at home potentially missing the mark in a new culture. And supply chains have to be adapted or rebuilt, presenting hurdles in communication, expectation and regulation that need to be identified and addressed.

A 2020 KPMG study of global manufacturing costs rated countries on ease of doing business — lower scores meant fewer regulatory and cost barriers. Switzerland (1.67) and the US (2.00) were among the least burdensome, while Mexico, India and Vietnam scored four or more, and Brazil reached five.

Since then, no single like-for-like “regulatory burden” index has been maintained, but recent World Bank data show the same pattern. On its 2023 Regulatory Quality Index (–2.5 to +2.5, rescaled here to 0–100 for clarity), Switzerland scores 84.6 and the US 77.8, while Mexico, India, Vietnam and Brazil cluster much lower, between 42 and 47.

Why expansion fails: three drivers of underperformance

This labyrinth of differences to the home territory is often concealed. While headline differences – such as India’s Digital Personal Data Protection Act (DPDP) – are easily spotted, these often represent the tip of a much more subtle iceberg. Indian workers, suppliers and society in general have different languages, experiences and cultural expectations than your own.

Why does this matter? With operational and product maturity, manufacturers often fall into the trap of assuming that their smooth workflows and production processes are the correct answer to a universal question. But what works brilliantly in, for example, the well-regulated environment of the European Union, can prove slow and unwieldy in developing nations, or might not reflect supply chain realities in South America.

Companies often expand without adjusting how they hire, sell, comply, or support customers locally. Assumptions about staffing, procurement, payments, compliance, and service levels fall apart in practice. Fixing those gaps takes time and budget, and early-stage businesses are least able to withstand the impact. 

Kingfisher’s Romanian exit


In late 2024, Kingfisher (the home improvement retailer behind B&Q, Brico Depot, etc.) announced it would exit the Romanian market by selling its Brico Depot Romania business to Altex Romania for about €70 million.

Kingfisher’s exit from Romania highlights how a weak cultural and market fit can undermine international expansion. The company misread the local DIY and home improvement landscape — from consumer preferences to competitive pressures — and failed to adapt its Brico Dépôt concept to Romania’s specific retail habits.

Brico Depot exterior
Kingfisher’s retreat from Romania stemmed from a poor cultural and market fit that left its Brico Dépôt chain struggling to gain traction. Despite £269 million in annual sales, the business posted losses and drained cash, while never reaching meaningful scale within the group.

This mismatch left stores underperforming, generating losses and cash outflows despite a notable sales footprint. With better localization during market research and rollout, Kingfisher might have tailored its offer, brand, and operations to local expectations. Instead, the misalignment drained resources and ultimately led the group to withdraw and refocus on stronger, better-aligned markets.

This isn’t a new phenomenon either. Nine years after entering the German retail market, Walmart called time on the territory. In retrospect, the US giant made several strategic mistakes, including failing to anticipate German consumer preferences for fresh foods, and assuming that consumers in a nation with strong public transport would want to drive to stores. Famously, the brand also assumed the American-style cheeriness of its staff would translate well, but German consumers found it off-putting, and even creepy.

Unlocalized operating models: the hidden fourth driver

So, why exactly does international expansion underperform? As we’ve touched on, territories differ from each other in three key areas: regulatory, culturally, and in terms of supply chain. Let’s look at each.

Regulatory mismatch

To state the obvious, laws differ across the world. Businesses seeking to enter new territories must be aware of local labor, environmental, safety and data-processing regulations. Often this goes beyond simply knowing what the statutes say; it demands a proper understanding of the intent of key laws designed to keep workers and consumers safe, and to protect the environment in which you want to do business.

Getting this wrong means more than just a regulatory slap on the wrists. Penalties can be severe. State safety regulators typically have the power to shut down a factory, at least temporarily. And firms suffering a data breach can expect severe fines: in the UK, for example, these can reach up to £17.5 million, or 4% of the business’ annual worldwide turnover, whichever is higher.

But the ramifications may go still further. For a foreign business, failure to understand and comply with a country’s laws can suggest a lack of care or seriousness, and lead to a reputational backlash. The poor translation of compliance and legal materials presents a real and significant legal risk.

Cultural barriers

The workforce in Germany, for example, is different to that in Brazil, or the Philippines. Each has its own language, but also its own culture, history and identity. On a day-to-day level, this can manifest itself in anything from the seriousness workers attach to instructions or protocols, or their expectations for remuneration packages or care and rest facilities. Internal comms and procedures, particularly around high-risk activities like plant operations, must reflect this to remain effective.

This point extends to onboarding and upskilling staff – particularly important to ensuring workplace competence and establishing a deep, localized skills base. Workforce engagement drops off when these programs lack local nuance, for example where a US-market onboarding video features a US personality without global or regional appeal.

The same is true for marketing. Whether selling direct to consumers, or supplying regional brands and wholesalers, manufacturers need to navigate different expectations and understanding. It’s true for sales too; the way businesses pursue leads, build relationships and complete deals with customers and suppliers must also be locally and culturally sensitive. And for support materials like instructions and user guides, clarity and accuracy in every language are essential to ensure safe and effective product use.

How GM’s Misreading of Australia Ended Holden’s Legacy

General Motors’ decision to retire the Holden brand and exit Australia in 2020 shows how a once-iconic manufacturer can lose relevance when it fails to adapt to local market change. For decades, Holden thrived by building cars suited to Australian tastes and conditions, but as buyers shifted sharply toward SUVs and pickups, GM was slow to respond.

After shutting down local manufacturing in 2017, it relied on imported models that often felt mismatched or overpriced and failed to meet Australians’ expectations. The company also abandoned long-term investment in right-hand-drive vehicles, making it impossible to supply competitive products for a relatively small but unique market.

As sales collapsed and costs to tailor vehicles rose, Holden went from national symbol to financial liability, forcing GM to withdraw entirely. Stronger localization — from product design to market research and supply chain strategy — might have preserved Holden’s position and prevented the loss of a storied brand.

Fragmented international supply chains

Manufacturing businesses can’t simply copy and paste their existing supply chain arrangements to new territories. Global expansion means both finding new partners, and working with existing ones in new ways. While this can drive cost savings – for example through greater volumes or reduced shipping costs – contractual issues can arise from linguistic or cultural misunderstandings. In the worst case, this results in delays, cost overruns or even failed deliveries, all of which can have catastrophic impacts on the venture’s success.

According to McKinsey research, supply chain disruptions lasting at least a month now occur on average every 3.7 years. These are expensive problems, on average costing organisations 45% of one year’s profits each decade.
Source: McKinsey research.

Poor multilingual coordination can more generally give rise to supply chain misalignment. Without clear – and clearly documented – understanding between parties, contracted quantities, timeframes and accountability can all be impacted. In today’s business environment, that can lead to anything from productivity losses, through to difficulties in accounting for Scope 3 emissions.

Plan for local realities: compliance, culture, cohesion
Manufacturers protect investments and improve expansion outcomes when they plan for local laws, labor norms, and customer expectations. Treat in-language content, market-specific processes, and quality checks as core parts of the operating model, rather than an afterthought.

• Legal and compliance: translate and adapt contracts, safety data sheets, labels, and policies; keep audit trails and version control.
• Labor and operations: tailor training and SOPs to local standards; align shift practices and safety requirements.
• Marketing and customer communication: use approved terminology; adapt offers, service levels, and support channels for each market.

Result: fewer delays and fewer audit issues, stronger team cohesion, and faster time to value in each region.

Localized regulatory compliance

Staying on-side in a new territory depends both on understanding local rules, and localizing existing policies to reflect local laws and enforcement expectations. This extends beyond simple translation; policies need changing and adapting, requiring regional expertise. A local legal review isn’t just a box-checking exercise, it’s a reputational and competitive safeguard.

Localized marketing and customer engagement

Again, adapting your messaging and marketing efforts to a new territory isn’t just an exercise in translation. It’s about gaining regional traction through regional resonance. This is a particularly important consideration when it comes to branding. Firms are understandably protective of identities they may have built over decades, but the strongest brands understand how to flex and adapt to suit regional cultures, without compromising their core identity.

This can be a challenging area, with businesses needing to look at how they win, service and retain clients through a new, localized lens. But a localized cultural approach is key, particularly as even apparently self-evident concepts can have different interpretations. Take the concept of ‘green’ business: in Europe it reflects ambitious climate targets, sustainable investment and a circular economy. In Southeast Asia, green policies consider sustainability within a more holistic approach that also values socio-economic development.

How the Phrase helps manufacturers communicate clearly at scale:

Phrase is an AI-powered language technology platform that delivers accurate, consistent multilingual content quickly and securely across global operations.

Phrase Orchestrator: Automate translation and review steps, route work to the right teams, and connect ERP, PLM, CMS, and helpdesk tools.

Phrase Portal: Give employees a secure, self-serve way to translate sensitive documents and requests.

Phrase Quality Technologies: Enforce terminology, run automated checks, and keep brand voice consistent across all content.

Optimized supply chain communication

Clear, in-language communication keeps supply chains moving. When policies, training, and support materials are translated and adapted for each region, local teams act quickly and confidently. That autonomy builds resilient networks that deliver value and support growth.

In time-sensitive and on-demand operations, real-time translation reduces friction in procurement, logistics, and audits. Multilingual dashboards surface global and local insights, helping manufacturers plan, execute, and adjust with fewer delays and errors.

A strategic partner for rapid expansion

See how Phrase helps Zendesk localize product, legal, knowledge base and training content across more than 30 languages, including real-time translations between customers and support agents.

Zendesk Case Study Feature Image

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Strategic takeaway: building expansion on a localized foundation

There are no shortage of horror stories of international growth gone wrong, from Kingfisher’s Romanian experience, to Barbie’s failure to conquer China. However, despite the complexity of the challenge, a great many businesses have taken on new territories and thrived. Success comes through meticulous planning, and depends on precursors including diligent market research and expert risk analysis.

“Phrase made our international expansion possible. It saved us time, money, and allowed us to scale faster than we ever thought possible.”

Vojtěch Studnička, expansion director, Trenýrkárna.cz

However, the whole enterprise must be underpinned by an informed, accurate and nuanced understanding of the marketplace. Success means asking questions of any territory: how does business work there? How are employees protected? What messages resonate, and which ones don’t?

Localization serves as both a conduit for the answers, and the lever through which strategy leaders, COOs and heads of supply chain can create the business’ successful response.

“Localization is no longer an afterthought – it’s a foundation for growth. The shift we’re seeing is from language as a service to language as strategy. And that’s a very different conversation.”

Georg Ell, CEO, Phrase

Manufacturers that succeed in new markets plan for localization as early as they plan for capital investment, plant design, or supply chain mapping. It is not a final step after market entry, but an enabling layer for every decision, from regulatory compliance to customer engagement.

Expansion fails when:

  • Laws are misunderstood or compliance is poorly localized.
  • Messaging and processes fail to resonate with local cultures.
  • Supply chains fragment under the strain of misaligned communication.
  • The operating model assumes “what works at home” will work everywhere.

Localization turns these risks into advantages:

  • Compliance processes are adapted, not just translated.
  • Marketing and customer engagement are shaped by regional values.
  • Supply chain communication becomes precise, timely, and multilingual.
  • Operating models flex to match local market realities.

Expansion is never just about moving products or processes into new regions. Success depends on embedding localization as a core layer of strategy — on par with capital investment, plant design, or supply chain mapping. Manufacturers that plan for it from day one transform risks into advantages: compliance that protects reputation, supply chains that scale with confidence, and customer engagement that resonates across cultures.

For today’s manufacturers,  the equation is simple: global ambition only delivers global success when grounded in local fluency. Localization is not an optional extra; it is the multiplier that turns expansion into long-term competitiveness.

Precision translation for manufacturing

Achieve faster, safer global growth with secure, high- quality multilingual content powered by AI. Phrase empowers manufacturing leaders with scalable, compliant translation solutions.

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